Apparatus for delivery of a predetermined amount of solid and gaseous carbon dioxide

ABSTRACT

Compositions and methods are provided for a system in which liquid carbon dioxide, or a mixture of liquid and gaseous carbon dioxide, is converted to solid carbon dioxide by exiting an orifice at a sufficient pressure drop, e.g., for delivery of carbon dioxide to a concrete mixture in a mixer.

CROSS-REFERENCE

This application is a continuation of U.S. patent application Ser. No.15/161,927, filed on May 23, 2016, which is a divisional of U.S. patentapplication Ser. No. 14/642,536, filed Mar. 9, 2015, which claimspriority to U.S. Provisional Patent Application Ser. Nos. 61/992,089,filed May 12, 2014; 62/086,024, filed Dec. 1, 2014; 62/083,784, filedNov. 24, 2014; 62/096,018, filed Dec. 23, 2014. U.S. patent applicationSer. No. 14/642,536 is also a continuation-in part of PCT ApplicationNo. PCT/CA2014/050611, filed Jun. 25, 2014, which is acontinuation-in-part of U.S. patent application Ser. No. 14/249,308 (nowU.S. Pat. No. 9,108,883), filed Apr. 9, 2014. Both PCT Application No.PCT/CA2014/050611 and U.S. patent application Ser. No. 14/249,308, claimpriority to U.S. Provisional Patent Application Ser. No. 61/839,312,filed Jun. 25, 2013, U.S. Provisional Patent Application Ser. No.61/847,254, filed Jul. 17, 2013, U.S. Provisional Patent ApplicationSer. No. 61/879,049, filed Sep. 17, 2013, U.S. Provisional PatentApplication Ser. No. 61/925,100, filed Jan. 8, 2014, and U.S.Provisional Patent Application Ser. No. 61/938,063, filed Feb. 10, 2014.Moreover, PCT Application No. PCT/CA2014/050611 also claims priority toU.S. Provisional Patent Application Ser. No. 61/980,505, filed Apr. 16,2014. Each of the abovementioned applications is entirely incorporatedherein by reference.

BACKGROUND OF THE INVENTION

Cement mixes, such as concrete mixes, are used in a multitude ofcompositions and procedures throughout the world. In addition,greenhouse gases such as carbon dioxide are a growing concern worldwide.There is a need for methods and compositions to contact cement mixeswith carbon dioxide and for cement mixes containing incorporated carbondioxide and carbonation products.

In certain situations in which a mixture of solid and gaseous carbondioxide is delivered by forcing pressurized liquid carbon dioxide, or amixture of gaseous and liquid carbon dioxide, through an orifice to alower pressure environment, it is desirable to determine the flow rateof the carbon dioxide and/or total amount of carbon dioxide deliveredwithout the use of, e.g., changes in weight of carbon dioxide sourcecontainer or containers, which can be inaccurate at small doses, or,e.g., a mass flow controller or other direct measurement of flow. Inaddition, it is often desirable to deliver such a mixture of solid andgaseous carbon dioxide to a mix, such as a cement mix, using apparatusand methods to optimize the uptake of the carbon dioxide into the mix,especially at low doses of carbon dioxide.

SUMMARY OF THE INVENTION

In one aspect, the invention provides apparatus. In certain embodiments,the invention provides an apparatus for determining a flow rate ofcarbon dioxide, comprising i) a delivery line through which flowsgaseous carbon dioxide, liquid carbon dioxide, or a combination ofgaseous and liquid carbon dioxide; ii) an orifice at the distal end ofthe delivery line, through which the carbon dioxide exits from thedelivery line, wherein the diameter of the delivery line as it joins theorifice is D_(p) and the diameter of the orifice is D_(o), and whereinD_(o) is less than D_(p); iii) a first temperature sensor proximal tothe orifice and configured to detect a first temperature, T, of carbondioxide in the delivery line and to transmit the detected firsttemperature to a flow rate calculation system; iv) a pressure sensorproximal to the orifice and configured to detect a pressure, P_(u), ofcarbon dioxide in the delivery line and to transmit the detectedpressure to the flow rate calculation system; v) a second temperaturesensor distal to the orifice and configured to detect a secondtemperature, T_(D), of carbon dioxide exiting the orifice and totransmit the detected second temperature to the flow rate calculationsystem. The apparatus of can further comprise vi) the flow ratecalculation system, wherein the flow rate calculation system isconfigured to a) at a first time, determine from T_(D) whether thecarbon dioxide in the delivery line when it reaches the orifice is 100%gas or 100% liquid, or a mix of gas and liquid, and b) calculate aninstantaneous flow rate for the first time, wherein 1) when the carbondioxide in the delivery line as it is delivered to the orifice is 100%gas or 100% liquid, the flow rate is calculated from D_(p), D_(o), andP_(u), and T for the first time and 2) when the carbon dioxide in thedelivery line as it is delivered to the orifice is a mixture of gas andliquid, the flow rate is calculated from D_(o), P_(u), T, and T_(D) atthe first time. The apparatus can further comprise a mixer for mixingconcrete or a container containing a material used in concrete, whereinthe apparatus is configured to deliver carbon dioxide to the mixer orthe container. In certain embodiments, the apparatus comprises a mixerfor mixing concrete, such as a transportable mixer, for example the drumof a ready-mix truck. In certain embodiments the mixer comprises astationary mixer. The apparatus can further comprise a conduit operablyconnected to the distal end of the orifice and configured to direct thecarbon dioxide to a destination. In certain embodiments, the conduit isattached to the ready-mix truck. In certain embodiments, not attached toa ready-mix truck. In certain embodiments, the flow rate calculationsystem is configured to calculate the flow rate of carbon dioxide at aplurality of times or time intervals, each of which has its own P_(u),T, and T_(D), which may be the same or different than the P_(u), T, andT_(D) of the other times. In certain embodiments, the flow calculationsystem is configured to calculate a total amount of carbon dioxide thathas flowed through the orifice based on the instantaneous flow rates forthe plurality of times or time intervals. In certain embodiments, theflow rate calculation system outputs the total amount of carbon dioxideto a system controller. In certain embodiments, the system controllercompares the total amount of carbon dioxide to a predetermined endamount of carbon dioxide, and when the total amount is equal to orgreater than the predetermined end amount, sends a signal to one or moreactuators configured to modulate the flow of carbon dioxide through theorifice to cause the one or more actuators to modulate the flow ofcarbon dioxide, for example to slow or cease flow of the flow of carbondioxide. In certain embodiments, the source of gaseous carbon dioxideand the source of liquid carbon dioxide are the same. In certainembodiments, the source of gaseous carbon dioxide and the source ofliquid carbon dioxide are different.

In certain embodiments the invention provides a system for deliveringcarbon dioxide to a drum of a ready-mix truck comprising (i) a rigid orsemi-rigid conduit comprising a proximal end and a distal end, whereinthe conduit is configured to be operably connected to a source of carbondioxide at its proximal end for delivery of the carbon dioxide from itsdistal end to a drum of a ready-mix truck; and (ii) a guide affixed tothe ready-mix truck, wherein the guide is configured to reversiblyattach the conduit to the ready-mix truck and to position the distal endof the conduit at a desired position in the drum of the ready-mix truckin order to deliver carbon dioxide from the carbon dioxide source toconcrete mixing within the drum. The guide can be configured to positionthe distal end of the conduit to within 10-40 cm of the surface of themixing concrete, on average, when the drum of the ready-mix truckcontains a full load of concrete. The system can further comprise thesource of carbon dioxide. The source of carbon dioxide can be a sourceof liquid carbon dioxide, and the system can further comprise an orificeoperably connected to the proximal end of the rigid or semi-rigidconduit, wherein the orifice is operably connected to the source ofcarbon dioxide and is configured to convert the liquid carbon dioxidefrom the source of carbon dioxide to solid and gaseous carbon dioxidefor delivery through the conduit to the concrete. The orifice can beoperably connected to the proximal end of the rigid or semi-rigidconduit by a flexible conduit, where the orifice is positioned at aproximal end of the flexible conduit and the proximal end of the rigidor semi-rigid conduit is attached to a distal end of the flexibleconduit. The orifice can comprise a temperature sensor for sensing thetemperature of the mixture of solid and gaseous carbon dioxide exitingthe orifice.

In another aspect, the invention provides methods.

In certain embodiments, the invention provides a method for determininga flow rate of carbon dioxide in a system where a mixture of liquid andgaseous carbon dioxide is delivered via a conduit to an orifice, whereinthe orifice has a cross-sectional area, and exits the orifice as amixture of gaseous and solid carbon dioxide, comprising (i) determininga first temperature, T_(D), of the carbon dioxide exiting the orifice;(ii) determining a pressure, P_(u) of the carbon dioxide in the conduitproximal to the orifice; (iii) determining a second temperature, T, ofthe carbon dioxide in the conduit proximal to the orifice; (iv) at afirst time, determining the proportions of liquid carbon dioxide in thetotal carbon dioxide delivered to the orifice from T_(D) at the firsttime; (v) determining the flow rate for the carbon dioxide delivered tothe orifice at the first time from P_(u), T, and T_(D) at the firsttime, and the diameter, D_(o), of the orifice, the proportion of liquidcarbon dioxide delivered to the orifice. In certain embodiments, thedetermining is performed in less than 100 ms. In certain embodiments,the determining is performed in less than 20 ms. In certain embodiments,the determining is performed in less than 5 ms. The method may furthercomprise performing steps (i) through (v) at least 100 times subsequentto the first time. The method may further comprise performing steps (i)through (v) at least 1000 times subsequent to the first time. In certainembodiments, a plurality of flow rates are determined at a plurality oftimes, and the total amount of carbon dioxide delivered is determinedfrom the plurality of flow rates and the times.

In certain embodiments, the invention provides a method of carbonating aflowable concrete mix comprising i) delivering carbon dioxide to theconcrete mix; wherein the carbon dioxide is delivered as a mixture ofgaseous and solid carbon dioxide for at least part of the delivery timewherein the carbon dioxide is delivered by a method comprising a) thecarbon dioxide is delivered via a delivery line with diameter D_(p) toan orifice with diameter D_(o), and through the orifice, optionally alsothrough a conduit attached to the orifice, to the concrete mix, b)carbon dioxide is supplied to the delivery line by flowing pressurizedgaseous carbon dioxide to the delivery line via a carbon dioxide gasline and/or flowing pressurized liquid carbon dioxide to the deliveryline via a carbon dioxide liquid line, so that at least part of thecarbon dioxide reaching the orifice during delivery of the carbondioxide to the concrete mix is liquid carbon dioxide, c) the carbondioxide exits the orifice as a gas, a solid, or a mixture thereof, ii)determining a total amount of carbon dioxide delivered to the concretemix by a method comprising a) determining a pressure of the carbondioxide, P_(u), in the delivery line proximal to the orifice at aplurality of times, b) determining a first temperature of the carbondioxide, T, in the delivery line proximal to the orifice at theplurality of times, c) determining a second temperature of the carbondioxide, T_(D), as it exits the orifice at the plurality of times;wherein, for each time of the plurality of times, all of P_(u), T, andT_(D) are measured at the same time, d) determining from T_(D) for eachtime whether the carbon dioxide in the delivery line when it reaches theorifice is 100% gas or 100% liquid, or a mix of gas and liquid, e)calculating an instantaneous flow rate for each time, wherein 1) whenthe carbon dioxide in the delivery line as it is delivered to theorifice for a time is 100% gas or 100% liquid, the flow rate iscalculated from D_(p), D_(o), P_(u) and T for that time, and 2) when thecarbon dioxide in the delivery line as it is delivered to the orificefor a time is a mixture of gas and liquid, the flow rate is calculatedfrom D_(o), P_(u), T, and T_(D) for that time, f) integrating the flowrates for the plurality of times to obtain a total amount of carbondioxide delivered; and iii) modulating the delivery of the carbondioxide to the concrete mix based at least in part on the total amountof carbon dioxide delivered determined in ii)f). In certain embodiments,the modulation of delivery of the carbon dioxide comprising halting thedelivery of carbon dioxide when the total amount of carbon dioxidedelivered is greater than or equal to a predetermined amount of carbondioxide.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1 shows a schematic representation of an exemplary orifice fordelivery of carbon dioxide.

FIG. 2 is a representation of carbon dioxide flow in a delivery line anddistal to an orifice at various points in a process for delivery ofcarbon dioxide. FIG. 2 a . Only gas valve open; FIG. 2 b . Gas andliquid valves open; FIG. 2 c . Only liquid valve open, temperature ofcarbon dioxide distal to orifice −20 to −56° C.; FIG. 2 d . Only liquidvalve open, temperature of carbon dioxide distal to orifice −56 to −78°C.

FIG. 3 shows a generalized representation of a carbon dioxide deliverysystem.

FIG. 4 shows a representation of one embodiment of a carbon dioxidedelivery system.

FIG. 5 shows one position at which the wand for carbon dioxide deliverycan be aimed in the drum of a ready-mix truck, at the second fin in thetruck on the bottom side of the drum.

FIG. 6 shows one example of a wand for delivering carbon dioxide to amixer, e.g., a drum of a ready-mix truck, and a holder or holster forinsertion and positioning of the wand. View 1: Top view showing (1) ¼″Aluminum handle with vacuum jacketed hose running from carbon dioxidedelivery system to lance; (2) ½″ Aluminum lance, same piece of aluminumas 1, that attaches to the concrete truck mount (3) ¼″ PVC to allow easyinsertion of the lance into the mount (4) metal plug to prevent PVC fromsliding off into the truck during mixing; (5) ¼″ Aluminum rod thatextends into the mixing drum; (6) ¼″ Steel mount that is welded to theconcrete trucks; (7) ¼″ Steel pipe to align the lance at the properangle into the mixing drum View 2: End view showing (8) Metal sensingproximity switch that triggers the carbon dioxide delivery system oncethe lance has been inserted. View 3: Side view showing (1) ¼″ Aluminumhandle with vacuum jacketed hose running from carbon dioxide deliverysystem to lance; (2) ½″ Aluminum lance, same piece of aluminum as 1,that attaches to the concrete truck mount (3) ¼″ PVC to allow easyinsertion of the lance into the mount (4) metal plug to prevent PVC fromsliding off into the truck during mixing; (5) ¼″ Aluminum rod thatextends into the mixing drum; (6) ¼″ Steel mount that is welded to theconcrete trucks; (7) ¼″ Steel pipe to align the lance at the properangle into the mixing drum

DETAILED DESCRIPTION OF THE INVENTION

The invention provides compositions and methods for delivering carbondioxide, e.g., to a concrete mixing operation; in certain embodimentsthe invention provides compositions and methods for determining a flowrate of the carbon dioxide by measurement of temperature and pressure.In particular, the invention provides compositions and methods fordelivering pressurized liquid and gaseous carbon dioxide to and throughan orifice from high pressure to low pressure, e.g., atmosphericpressure, causing the liquid carbon dioxide to become a mixture of solidand gaseous carbon dioxide. Solid carbon dioxide is also referred to as“dry ice” herein. When a mixture of solid carbon dioxide and gaseouscarbon dioxide is formed as a result of a sudden release of pressure ofa liquid carbon dioxide, the solid carbon dioxide in the mixture is alsoreferred to herein as “snow.” The invention further providescompositions and methods for measuring the rate of delivery of carbondioxide through the orifice that combine temperature and pressuremeasurements at various points to determine a total amount of carbondioxide delivered. Control systems can be used to cause the flow to stopafter a desired amount of carbon dioxide has been delivered through theorifice.

The compositions and methods of the invention find use anywhere that itis desired to deliver carbon dioxide, especially in the form of a mix ofgaseous and solid carbon dioxide, and most especially in smalleramounts; in certain embodiments the methods and compositions of theinvention include methods and compositions for delivery of carbondioxide to a concrete mix, such as in a concrete mixer (e.g., a drum ofa ready-mix truck, or a stationary mixer such as at a precast plant) orelsewhere, or to a component of a concrete mix, and for convenience theinvention will be described in terms of these embodiments, however, itis understood that aspects of the invention, such as determining flowrates of carbon dioxide, are not confined to delivery of carbon dioxideto concrete mixes or components of concrete mixes and may be used in anyoperation in which carbon dioxide delivery, especially delivery ofgas/solid carbon dioxide mixture, and/or measurement of flow rate and/ortotal amount delivered is desired. It is especially useful in systems inwhich a relatively small dose of carbon dioxide is desired, e.g., asystem in which other means of determining total amount of carbondioxide delivered, for example, by measuring the change in weight ormass of the carbon dioxide container, are not accurate enough to provideuseful information; it will also be appreciated that measuring thechange in weight of the source container is not an accurate measure ofcarbon dioxide actually delivered if any carbon dioxide in the deliveryline is vented during delivery. It is also useful when the use of a masscontroller, with concomitant necessity for pure liquid or pure gas inthe delivery line at the point of flow measurement, is not feasible ordesirable.

In general, carbon dioxide delivery in which flow is determined bycertain compositions and methods of the invention involves the followingsteps: first, a delivery line with an orifice at its distal end ispressurized by introduction of gaseous carbon dioxide into the deliveryline, to pressurize the line sufficiently that when liquid is introducedinto the line, the pressure drop will not be such that solid carbondioxide is formed, e.g., pressurized to a certain minimum pressure thatis such that the pressure difference between it and the pressure of theliquid carbon dioxide is not sufficient to cause solid carbon dioxideformation; often a certain safety cushion is added to the minimumpressure to ensure that no solid carbon dioxide forms. Next, liquidcarbon dioxide is introduced into the delivery line; the gas flowcontinues briefly to ensure that there is no drop in pressure, and isthen halted so that only liquid is supplied to the delivery line. Whenit is desired to halt the liquid flow, gaseous carbon dioxide is againbriefly introduced into the delivery line and the delivery of liquidcarbon dioxide to the line is halted. The burst of gas into the lineserves to push all liquid out of the orifice. Thus, in sequence duringthe simplest case of delivery of carbon dioxide to the orifice, only gasis delivered, a mixture of gas and liquid is delivered, only liquid isdelivered, a mixture of gas and liquid, and finally only gas. On exitingthe orifice, the liquid carbon dioxide experiences a pressure changefrom high pressure in the delivery line (e.g., 300 psi) to atmosphericpressure. The liquid is not stable at atmospheric pressure and itundergoes a transition to gas and solid carbon dioxide.

An exemplary orifice is illustrated in FIG. 1 . The dimensions are foruse in delivering carbon dioxide to a concrete mix for carbonation ofthe mix and are those useful in that operation, where a total dose of1-5 L of liquid carbon dioxide may be delivered over a period of lessthan 5 minutes. It will be appreciated that smaller dimensions may beused for lower doses and larger dimensions for higher doses, and anysuitable dimensions may be used. Of note is that the orifice comprises aconnection for a temperature sensor, which measures the temperature ofthe carbon dioxide exiting the orifice; the carbon dioxide exiting theorifice is referred to herein as distal to the orifice or downstream ofthe orifice. In the orifice illustrated in FIG. 1 , liquid CO₂ entersthe orifice at the 5/64″ diameter end. The ¼″ National Pipe Thread Taper(NPT) connection is for a temperature sensor. The ½″ NPT connection isfor connection of a conduit to direct the carbon dioxide exiting theorifice to the desired location. For example, the conduit may be used todirect carbon dioxide to a particular location in a concrete mixer, suchas a particular location in a drum of a ready-mix truck. Certainembodiments of the invention provide one or more of an orifice asdescribed, a conduit operably connected to the orifice to direct thecarbon dioxide exiting the orifice, and, in some embodiments, a systemfor positioning the conduit so as to direct the carbon dioxide to aparticular location, for example, a particular location in a drum of aready-mix truck; the conduit apparatus may be affixed to the drum in apermanent or, preferably, temporary configuration. Certain embodimentsof the invention provide for the positioning system itself, alone oraffixed to a mixer, e.g., a ready-mix truck, or a plurality ofpositioning systems, each affixed to a separate mixer, e.g., to separateready-mix trucks. Thus, for example, in a ready-mix operation, eachtruck that is designated as a potential receiver of carbon dioxide mayhave its own positioning system, e.g., a holster, affixed thereto insuch a location as to position the conduit to deliver carbon dioxide toa desired location inside the drum of the truck while concrete is mixingin the drum, so that the conduit may be temporarily attached todifferent ready-mix trucks as desired to deliver carbon dioxide to thedifferent trucks. Hence, in certain embodiments, the invention providessystems and methods for delivery of carbon dioxide to the drums of oneor more ready-mix trucks where each truck to which carbon dioxide is tobe delivered has affixed thereto a positioning system that travels withthe truck, and a carbon dioxide delivery systems, for example asdescribed herein, that includes a conduit for delivery of carbon dioxidefrom a source of carbon dioxide to the ready-mix truck, where eachpositioning system is affixed in a location and position such that theconduit may be temporarily attached to the truck and positioned in sucha way as to allow carbon dioxide to be delivered to a desired locationwithin the drum of the truck, for example, while concrete is mixing inthe drum of the truck. Locations and positioning may be as describedherein. The system may include at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,12, 15, 20, 25, 30, 40, or 50 separate ready-mix trucks, each with itsown positioning system attached, and 1 or, in some cases, more than 1,such as 2, 3, 4, 5, or more than 5 carbon dioxide delivery systems thatinclude a conduit that may be temporarily attached to the trucks fordelivery of carbon dioxide from a source of carbon dioxide to the drumof the truck. The carbon dioxide delivery system may be positioned, whenin use, at a location where the truck or trucks normally halt for aperiod sufficient to deliver a desired dose of carbon dioxide to theconcrete in the truck, for example, at a location where the trucksnormally halt for at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes. Forexample, the delivery system may be positioned at a wash rack in abatching facility. In this way, carbon dioxide can be delivered to thetrucks without significantly altering the time the trucks remain in thebatching facility, as it is delivered during an operation that wouldnormally take place, e.g., washing the trucks, and the only potentialadditional time would be in the attachment and detachment of theconduit, and in some cases the starting and stopping of delivery of thecarbon dioxide, if done by the truck driver. Thus, the system andmethods may allow delivery of a desired dose of carbon dioxide to theready-mix trucks, such as a dose of 0.05-2% bwc, or any other dose asdescribed herein, without prolonging the average time that a truckremains in the batching facility by more than 1, 2, 3, 4, 5, 6, 7, 8, 9,or 10 minutes, for example, by no more than 2 minutes, or no more than 4minutes, or no more than 6 minutes, on average. The carbon dioxidedelivery system may be a liquid delivery system and further include anorifice that allows liquid carbon dioxide, or a mixture of liquid andgaseous carbon dioxide, under pressure, to be converted to solid andgaseous carbon dioxide as it passes through the orifice to an area oflower pressure, for example, to an area of atmospheric pressure, asdescribed herein. Systems and methods for monitoring the flow of carbondioxide, such as those described herein, may be included in the systemsand methods of delivering carbon dioxide to the drums of ready-mixtrucks. Systems and methods for controlling the flow of carbon dioxide,such as those described herein, such as starting, stopping, and/orotherwise modulating the flow, may be included in the systems andmethods of delivering carbon dioxide to the drums of ready-mix trucks.

The compositions and methods of the invention include determination of aflow rate of carbon dioxide by measuring a temperature and a pressure inthe delivery line proximal to the orifice; a temperature of thedelivered carbon dioxide distal to the orifice is also measured todetermine what proportion of liquid and gaseous carbon dioxide is beingdelivered to the orifice; if the delivery line diameter and the orificediameter are known, the flow rate for liquid carbon dioxide and forgaseous carbon dioxide may be calculated; integration of the flow rategives total amount of carbon dioxide delivered through the orifice in agiven time. The temperature distal to the orifice is used to determinewhich phase (liquid or gas or both) is in the line and the equationsettings are changed based on the phase to calculate the instantaneousflow rate. Integrating the flow over time allows the total amount ofcarbon dioxide delivered in that time to be calculated. In some cases apressure distal to the orifice may also be used, if the pressure cannotbe assumed to be atmospheric.

The temperature distal to (downstream of) the orifice is used in thefollowing manner: When only the liquid valve is open in the system,85-100% liquid is flowing through the orifice and allowed to expand toatmospheric pressure, a temperature at or below −56° C. is seen in thestream exiting the orifice. When 100% gas, e.g., from the head spaceabove the liquid in a liquid pressurized portable liquid carbon dioxidetank (such as a Dewar) or other pressurized gaseous CO₂ source, isallowed to expand to atmospheric pressure, the resulting temperatureseen in the stream exiting the orifice is at or above that given by theequation:Pressure=544.181e^0.0324*Temp(° C.)Above this temperature, the flow distal to the orifice is 100% gas,below this it is a mixture of gas and solid (meaning some liquid isflowing through the orifice) until a temp of −56° C. is reached, atwhich the flow to the orifice is 100% liquid. If the temperature distalto the orifice is between these values one may interpolate between thetwo temperatures to determine the % liquid vs gas being delivered to theorifice. This is a linear relationship, or can be estimated orrepresented as a line.

FIG. 2 illustrates various exemplary times in a carbon dioxide deliveryprocess and the content of the delivery line (gas, liquid, mixture ofgas and liquid) as well as the composition of the carbon dioxide exitingthe orifice (gas, mixture of gas and solid), and the temperaturesassociated therewith. In FIG. 2 a , the gas line valve is opened and gaspurges the delivery line and brings it up to pressure. The gas is nocolder than the temperature at which carbon dioxide would liquefy at thepressure in the line, e.g., no colder than −20° C. at 300 psi, and thecarbon dioxide exiting the orifice is in gaseous form. Because theorifice diameter is much less than the diameter of the delivery line,the delivery line can be pressurized due to the back pressure at theorifice without closing off the orifice. In FIG. 2 b the liquid valve isopened and the gas valve remains open in order to assure that thepressure remains high; there is a co-flow of gas and liquid in thedelivery line. The temperature distal to the orifice decreases as liquidcarbon dioxide is converted to solid and gas, and the carbon dioxideexiting the orifice is a mixture of gas and solid. In general thisperiod is brief, as the gas valve quickly closes once the liquid valveopens, since it is no longer needed to keep the line pressurized. Thetemperature distal to the valve is between that of the gas and theliquid (−20 to −56° C.), depending on the proportions of gas and liquidreaching the orifice. In FIG. 2 c , the gas valve has closed and onlythe liquid valve is open, and during this interval the remaining gas inthe line is pushed out by liquid flow, so there is still a mixture ofgas and liquid in the delivery line, (FIG. 2 c shows only the liquid inthe line, but it is preceded by a liquid/gas mixture). The temperaturedistal to the orifice reflects that flow is still not 100% liquid whilethe gas/liquid mixture is pushed out, and the proportion of gas andliquid in the carbon dioxide reaching the orifice can be determinedbased on the temperature distal to the orifice. This period is alsobrief, as it continues only until all gas is pushed out of the line, anda mixture of gas and solid dioxide exits the orifice. In FIG. 2 d , onlythe liquid valve is open, all gas has been pushed out of the line, andthere is full liquid flow in the delivery line to the orifice. Theliquid carbon dioxide converts to approximately 50% gas and 50% solidcarbon dioxide after orifice; this can range from about 40% to 60% soliddepending on temperature and pressure. This period can be any desiredperiod, e.g. if a large amount of carbon dioxide is to be delivered theperiod of 100% liquid flow in the delivery line can be long; for a smalldose of carbon dioxide, the period can be brief. The temperature distalto the orifice will be between that of the liquid (−56° C.) and thesolid carbon dioxide (−78° C.), depending on the proportions of gas andsolid in the carbon dioxide exiting the orifice.

Not shown in FIG. 2 is the shutdown procedure, in which the gas valveopens, then the liquid valve closes, so that, again, both gas and liquidare in the delivery line and finally just gas, as the last of the liquidis forced out of the orifice, with the mixture of gas and solid andtemperature of the mixture exiting the orifice reflecting the proportionof gas and liquid in the line. The final portion of carbon dioxide inthe delivery line and exiting the orifice will be 100% gas, just as atthe beginning of the delivery process.

It will be appreciated that when only the liquid valve is open and allgas from the period when the gas valve was opened is flushed from thesystem, the carbon dioxide in the delivery line that reaches the orificecan nonetheless be a mixture of liquid and gaseous carbon dioxide due toformation of gaseous carbon dioxide from liquid in the line, for avariety of reasons; for example, temperature losses in the supply line,from the liquid source to the delivery system, or pressure drops throughpiping and fittings due to changes in diameter. Thus, it cannot beassumed that flow is 100% liquid even after the gas valve has beenclosed for a significant time, and the downstream (distal) temperaturemust be relied on to establish the fraction of carbon dioxide in thedelivery line as it reaches the orifice that is liquid vs. gas.

In addition, although the process has been described as one cycle,during any given period of carbon dioxide delivery it may be desired tomodulate the delivery rate of the carbon dioxide. Since liquid carbondioxide is approximately 500 times more dense than gaseous carbondioxide, the gas valve may be opened to introduce gas into the carbondioxide in the delivery line, with or without closure of the liquidvalve, thus decreasing the proportion of liquid and decreasing deliveryrate for the carbon dioxide.

The proportion of gas and liquid flow in the delivery line can bedetermined based on the temperature of the carbon dioxide exiting theorifice; for one-phase flow in the line, e.g., either 100% liquid flowor 100% gas flow, the equations below may be used to determine flow rateat any given time:F _(g) =O _(c)*15.4879*D _(o)^2*SQRT(16.086*ρ_(g)*(P _(u)+14.7))

-   -   used only when flow to orifice is one phase, 100% gas        F _(L)=(64*D _(o))^2*1.488*P _(u)^0.7022    -   used only when flow to orifice is one phase, 100% liquid        ρ_(g)=((P        _(u)+14.7)*0.04401*101325*1.8)/(14.7*0.993*8.314*(T+460))        O _(c)=0.84−(0.1636*P _(r))        P _(r)=(P _(d)+14.7)/(P _(u)+14.7)        P _(d)=(P _(u) *O _(r))/(1−O _(r))        O _(r)=(D _(o) /D _(p))^4        where F_(g)=Gas Flow (standard liters per minute, SLPM);        F_(L)=Liquid Flow (SLPM); O_(c)=Orifice Critical Flow; ρ_(g)=Gas        Density; P_(u)=Upstream Pressure; T=Upstream Temperature in °        C.; P_(r)=Pressure Ratio; P_(d)=Downstream Pressure;        D_(o)=Orifice Diameter; D_(p)=Pipe Diameter; and O_(r)=Orifice        Ratio

As described, when flow in the delivery line is nominally 100% liquidflow (i.e., liquid valve open, gas valve shut, all gas flushed fromline), the actual flow can vary between about 85-100% liquid flow, thatis, due to various conditions, up to 15% of the liquid in the line canconvert to gas, assuming liquid up to the orifice and not heating in theline; if the supply line heats up due to, e.g., ambient temperature,etc., than this can be >15%. In addition, the percentage of carbondioxide exiting the orifice that is solid can vary from 40-60% of thetotal carbon dioxide. Under conditions where the carbon dioxide in thedelivery line as delivered to the orifice contains both the gas and theliquid phase, the following equation is used to determine flow at agiven time:F _(2P) =O _(A)*19.7203*((SQRT((2*(P _(u)+14.7)*101325*ρ_(L))/(14.7*%LCO₂*0.01))*SQRT(C _(2P2)+(((100−% LCO₂)*ρ_(L)*0.55843)/(%LCO₂*ρ_(g)))))/(C _(2P1)+(((100−% LCO₂)*ρ_(L)*1.5839)/(% LCO₂*ρ_(g)))))used when flow to orifice is mixture of gas and liquid (2 phase)ρ_(L)=(44.01*2.768)/(0.26212^((1.0−((T+273.15)/304.21)^0.2908)+1.0)X _(s)=−0.00054863P _(u)+0.653 (solid can be 40-60%)X _(L)=−0.0031774T _(D)(° C.)+0.82116 (liquid can be 85-100%)ρ_(L)=(44.01*2.768)/(0.26212^((1.04T+273.15)/304.21))^0.2908)+1.0)X _(s)=−0.00054863P _(u)+0.653 (solid can be 40-60%)X _(L)=−0.0031774T _(D)(° C.)+0.82116 (liquid can be 85-100%)100*X _(L)=% LCO₂C _(2P1)=0.55^(−1.0/L)C _(2P)2=(1.0−(0.55^((L−1.0)/L)))*(L−1.0))where F_(2P)=2 Phase Flow; ρ_(L)=Liquid CO₂ Density; O_(A)=Orifice Area;% LCO₂=Percent Liquid CO₂=100*X_(L); X_(s)=Fraction of Solid CO₂ intotal carbon dioxide exiting the orifice; X_(L)=Fraction of Liquid CO₂in total carbon dioxide delivered to the orifice; T_(D)=DownstreamTemperature; P_(u)=Upstream Pressure; T=Upstream Temperature in ° C.;ρ_(g)=Gas Density; C_(2P1)=Coefficient of 2 Phase Flow 1; andC_(2P2)=Coefficient of 2 Phase Flow 2

L=Coefficient of Expansion, from Table 1 and appropriate interpolationor extrapolation. See Hesson, J. C. and Peck, R. E., Flow of Two-phaseCarbon Dioxide Through Orifices, American Institute of ChemicalEngineers Journal Vol. 4, No. 2, June 1958, pg. 207-210:

TABLE 1 Coefficient of Expansion at various % LCO₂ % LCO₂ L 0-80 1.0 901.1 95 1.3 97.5 3.0

The flow rate can be determined for a succession of times; the intervalbetween one flow determination and another is limited only by the speedat which values for P_(u), T, T_(D) may be determined and the speed atwhich the calculations to determine flow performed. In certainembodiments, the interval between flow rate determinations is 0.01-100ms, for example, 0.1-10 ms, such as 0.5-5 ms. At a time interval of 1millisecond (ms) between flow rate determinations, 1000 determinationsper second may be made. For a succession of flow rates, flow rate may beintegrated over time to give total carbon dioxide delivered in thattime.

The calculations to determine flow rate and/or total amount of carbondioxide delivered in a given time may be performed by any suitableapparatus capable of the requisite speed of calculation, such as acomputer, e.g., a programmable logic controller (PLC). It will beappreciated that the calculation apparatus will perform calculationsbased on the inputs it receives for P_(u), T, and T_(D) at anyparticular time, but, due to the fact that each is measured by adifferent sensor and transmitted to the calculation apparatusseparately, the actual time of each measurement for P_(u), T, and T_(D)may be slightly different; for the purposes of this description,measurements of P_(u), T, and T_(D), and any other measurements that maybe used in the calculation of a flow rate, are considered to be at “thesame time” if they are all used by the calculation apparatus tocalculate a flow rate for that time, even though they may not have beenmeasured at precisely the same time or at precisely the time at whichthe calculation apparatus performs the calculation.

Any suitable apparatus, as known in the art or that may be developed,may be used to deliver the gaseous and liquid carbon dioxide to thedelivery line and to determine the temperatures and pressure proximal(upstream) to the orifice and temperature distal (downstream) of theorifice (and, optionally, pressure downstream of the orifice if itcannot be assumed to be atmospheric pressure), and, as described above,to perform the necessary calculations to determine a flow rate and/ortotal amount of carbon dioxide delivered. The source of the gaseouscarbon dioxide may be any suitable source, such as a container thatcontains both liquid and gaseous carbon dioxide and from which gaseouscarbon dioxide can be withdrawn. For smaller operations, the containercan be, e.g., a pressurized portable liquid carbon dioxide tank (such asa Dewar). The source of the liquid carbon dioxide may be any suitablesource, such as a container that contains liquid carbon dioxide and fromwhich liquid carbon dioxide can be withdrawn. For smaller operations,the container can be, e.g., a pressurized portable liquid carbon dioxidetank (such as a Dewar). The sources may be the same, e.g., a containerthat contains both liquid and gaseous carbon dioxide where the gaseouscarbon dioxide is withdrawn at one port and the liquid carbon dioxide atanother.

Certain embodiments of compositions of the invention may be understoodin reference to FIG. 3 : A gas line [102] and liquid line [104] areinput into the valve assembly. Each line has a ball valve [106],pressure gauge [108] and pressure relief valve [110] leading into asolenoid valve, sometimes referred to herein as a solenoid. When CO₂ isto be delivered through the orifice, the gas solenoid [112] opensbriefly, e.g., for 0.1-10 seconds, to pressurize the piping prior toopening the liquid valve. Once the outlet line is pressurized the liquidsolenoid [114] opens and the gas solenoid [112] closes soon thereafter,e.g., 0.1-5 seconds later; in certain cases, the liquid solenoid and gassolenoid may open at the same time, depending on the pressure in theline. When the liquid valve is to close, the gas solenoid [112] opensbriefly, e.g., for 0.1-5 seconds (or longer, depending on the distancebetween the solenoid and the orifice; the time is sufficient to emptythe line, which will depend on the configuration), and the liquidsolenoid [114] closes. The gas solenoid [112] remains open for anotherbrief period, e.g., for 0.1-10 seconds. Prior to liquid injection gas isused to pressurize the pipe between the solenoid and the orifice [122]to ensure that pressure is sufficient to ensure that the incoming liquidremains liquid. After the liquid injection phase, the gas is used topush all the liquid out of the orifice and clear the liquid from thepipe between of the solenoid and the orifice. Feedback that confirms100% gas flow based on temperature determined by the downstreamthermocouple may be used.

Both the gas and liquid are forced through an orifice [122] in order toobtain the desired flow rate. During some, or preferably the entire,injection progress (gas-liquid-gas), pressure and temperature aremeasured and an equation is used to calculate the flow through theorifice, for example, to determine the amount of CO₂ injected, asdescribed above. A temperature sensor [118] and a pressure sensor [120]act in-line ahead of (proximal to) the orifice and feed information intoa calculating system, for example, a programmable logic controller, PLC[128]. Some or all of the mechanical valves can be controlled by a PLCand some or all of the sensors can be read by a PLC. The 2 solenoids[112 and 114] open and close (using the sequence described above) tocontrol the flow rate and the average is measured and is used tocalculate the amount of CO₂ dosed. A temperature sensor [124] measuresthe flow temperature immediately after the orifice [122] to determine ifthe CO₂ is in the liquid phase, gaseous phase or is a mixture of thetwo, recognizing that this has a major impact on the flow rate (e.g., ata certain pressure in the line and for a certain orifice, 25 SLPM gasvs. 1800 SLPM liquid). This post-orifice sensor is used to determinewhich phase (liquid or gas) is in the line and change the equationsettings between liquid and gas, or mixed liquid and gas, to calculatethe instantaneous flow rate. Integrating the flow over time allows thetotal flow to be calculated. The density of liquid is approximately 500times greater than that of gas; therefore there is a drastic differencebetween the flow rate of 100% liquid and 100% gas. One or more pressuresensors (gauges) distal to the orifice may also be included (not shown),especially if the orifice opens into a conduit of sufficient length thatthe pressure immediately after the orifice is not atmospheric, so thatcalculations may be adjusted based on actual pressure distal to theorifice.

Further inputs and outputs can be used, as desired or suggested by theintended use of the system. For example, when used as a carbon dioxidedelivery system for a concrete production facility, an operator caninteract with the PLC of the carbon dioxide delivery system with a humanmachine interface (HMI) [132], which can be any suitable HMI, forexample a touch screen. The operator can perform any suitable operationto send input to the delivery system PLC, for example by selecting arecipe using the HMI touch screen. The input could cause the deliverysystem PLC to issue the appropriate commands to, e.g., fill theheadspace of a concrete mixer with carbon dioxide, then reduce the flowrate to take up the remaining mixing time to achieve the desired CO₂dose. The carbon dioxide delivery cycle and the mixing cycle can besynchronized by using signals from the concrete facility's process PLC[134], which can be input to the delivery system PLC [128].

In certain embodiments, the carbon dioxide amount to be delivered is apredetermined amount and the carbon dioxide delivery system opens andcloses the appropriate valves based on flow rate and time. In certainembodiments additional, or alternative, inputs are used to modify theflow of carbon dioxide, for example, based on inputs from the concretemixing operation. Thus, for example, the system can use input from oneor more sensors [136, 138, 140] to modify the flow rate and mix time.For example, these can be CO₂ sensors located at leak points outside themixer that detect CO₂ concentration, and if the CO₂ concentration and/orrate of change of CO₂ concentration, passes a certain threshold or someother parameter, the flow of carbon dioxide is modulated, e.g., reducedor ceased. Such CO₂ sensors could be an important part of the dosinglogic in a precast system, e.g., a masonry mixer injection system, butwould likely mainly be present for safety in, e.g., ready-mixoperations. It can alternatively or additionally include a mixertemperature sensor if the temperature of the concrete mixer can be usedas feedback. It can alternatively or additionally include a concreterheology measurement sensor. The sensors can shut the system off if thesensors measure a property that crosses a set threshold or otherparameter. The system can also be run in manual mode and be set at aflow rate and then turned on for a given period of time. See U.S. patentapplication Ser. No. 14/249,308, filed Apr. 9, 2014, and PCT ApplicationNo. PCT/CA 2014050611, filed Jun. 25, 2014, for a further description ofcontrol systems that can be used with the apparatus and methodsdescribed herein.

One embodiment of an apparatus of the invention used in deliveringcarbon dioxide to concrete mixers to carbonate the concrete is shown inFIG. 4 . In FIG. 4, 200 =CO₂ Piping Assembly; 202=Fitting—½″ MNPT×½″FNPT Swivel nipple; 204=Valve—½″ FNPT Ball Valve; 206=Fitting—½″ MNPTnipple; 208=Fitting—½″ MNPT×½″ 2FNPT Swivel tee; 210=Fitting—½″ FNPT×½″2FNPT Swivel tee; 212=Valve—½″ MNPT Pressure Relief Valve (PRV) 400 psi;214=Fitting—½″ MPNT×¼″ FNPT bushing; 216=Gauge—¼″ MNPT Pressure Gauge(400 psi MAX); 218=Valve—½″ FNPT Brass Solenoid Valve (high pressurerated); 220=Fitting—½″ MNPT×4½″ nipple; 222=Valve—½″ FNPT StainlessSteel Solenoid Valve (cryo liquid rated); 224=Valve—½″ FNPT Check Valve;226=Fitting—½″ MNPT×½″ 2FNPT Tee; 228=Nozzle—Stainless Steel Orifice;230=Probe—¼″ MNPT Thermocouple Probe; 232=Fitting—½″ MNPT Thermowell;234=Probe—½″ MNPT Temperature Probe; 236=Transmitter—¼″ MNPT PressureTransmitter; 238=Fitting—½″ FNPT×½″ MNPT Pipe Adapter; 240=Fitting—½″MNPT×4″ nipple; 242=Fitting—½″ FNPT×½″ FNPT Sw nipple; 244=Fitting—½″MNPT×3″ nipple; 246=Fitting—½″ FNPT coupling; 248=Nipple—½″ MNPT×2½″nipple; and 250=Transmitter—Temperature Transmitter.

Carbonation of Concrete Mixes

In certain embodiments, the invention provides compositions and methodsfor carbonation of concrete mixes or components of concrete where thecarbon dioxide is delivered as described herein and, optionally, theflow rate and total amount of carbon dioxide delivered to the mix isdetermined as described herein.

Cement mix operations are commonly performed to provide cement mixes(concrete) for use in a variety of applications, the most common ofwhich is as a building material. Such operations include precastoperations, in which a concrete structure is formed in a mold from thecement mix and undergoes some degree of hardening before transport anduse at a location separate from the mix location, and ready mixoperations, in which the concrete ingredients are supplied at onelocation and generally mixed in a transportable mixer, such as the drumof a ready mix truck, and transported to a second location, where thewet mix is used, typically by being poured or pumped into a temporarymold. Precast operations can be either a dry cast operation or a wetcast operation, whereas ready mix operations are wet cast. Any otheroperation in which a concrete mix is produced in a mixer and exposed tocarbon dioxide during mixing is also subject to the methods andcompositions of the invention. By “exposed to carbon dioxide” andsimilar phrases, as used herein, is meant exposure of the concrete mixto carbon dioxide at a concentration above that found in the atmosphere;usually at least 10-fold higher than atmospheric concentrations.Commercial sources of carbon dioxide of suitable purity are well-known.In certain embodiment, the carbon dioxide is 95-100% pure. The carbondioxide may be commercially supplied high purity carbon dioxide. In thiscase, the commercial carbon dioxide may be sourced from a supplier thatprocesses spent flue gasses or other waste carbon dioxide so thatsequestering the carbon dioxide in the cement mix, e.g., hydrauliccement mix sequesters carbon dioxide that would otherwise be agreenhouse gas emission.

The methods in certain embodiments are characterized by contactingcarbon dioxide with wet cement binder, e.g., hydraulic cement, in amixer at any stage of the mixing, such as during mixing of the cementwith water, or during the mixing of wetted cement with other materials,or both. The cement may be any cement, e.g., hydraulic cement capable ofproducing reaction products with carbon dioxide. For example, in certainembodiments the cement includes or is substantially all Portland cement,as that term is understood in the art. The cement may be combined in themixer with other materials, such as aggregates, to form acement-aggregate mixture, such as mortar or concrete. The carbon dioxidemay be added before, during, or after the addition of the othermaterials besides the cement and the water. In addition oralternatively, in certain embodiments the water itself may becarbonated, i.e., contain dissolved carbon dioxide.

In certain embodiments, the carbon dioxide is contacted with the cementmix, e.g., hydraulic cement mix during mixing by contact with thesurface of the mixing cement mix, e.g., hydraulic cement mix, that is,it is released from an opening or openings that is/are positioned sothat the carbon dioxide is initially contacted over the surface of theconcrete. As used herein, “contacted with the surface of the cement mix”and similar phrases encompasses embodiments in which the opening isclose enough to the surface that there may be occasional contact withthe surface of the mixing concrete and even temporary submersion underthe surface, so long as the average distance of the opening from thesurface is such that, on average, the carbon dioxide released iscontacted with the surface and not underneath the surface. Without beingbound by theory, it is believed that the carbon dioxide contacted withthe surface of the cement mix, e.g., hydraulic cement mix dissolvesand/or reacts in the water, and is then subsumed beneath the surface bythe mixing process, which then exposes different cement mix, e.g.,cement mix, to be contacted, and that this process continues for as longas the wetted hydraulic cement is exposed to the carbon dioxide. It willbe appreciated that the process of dissolution and/or reaction maycontinue after the flow of carbon dioxide is halted, since carbondioxide will likely remain in the gas mixture in contact with the cementmix, e.g., hydraulic cement mix. In embodiments in which liquid carbondioxide is used to produce gaseous and solid carbon dioxide, the solidcarbon dioxide will sublimate and continue to deliver gaseous carbondioxide to the cement mix, e.g., hydraulic cement mix after the flow ofliquid carbon dioxide has ceased. This is particularly useful in readymix truck operations, where there may be insufficient time at thebatching facility to allow uptake of the desired amount of carbondioxide; the use of liquid carbon dioxide which converts to gaseous andsolid carbon dioxide allow more carbon dioxide to be delivered to themix even after the truck leaves the batching facility. It will beappreciated that the dissolution of the carbon dioxide in the mix water,and its reaction with components of the concrete mix to produce reactionproducts, such as intermediates and final reaction products, will, ingeneral, continue after mixing of the concrete materials and carbondioxide has stopped, that is, will not be complete even after, e.g., theconcrete mix is poured or otherwise used at a job site. In other words,mixing is halted before a chemical reaction between the carbon dioxideand the concrete materials is complete.

The carbon dioxide may be contacted with the cement mix, e.g., hydrauliccement mix such that it is present during mixing by any suitable systemor apparatus. In certain embodiments, gaseous or liquid carbon dioxideis supplied via one or more conduits that contain one or more openingspositioned to supply the carbon dioxide to the surface of the mixingcement mix, e.g., hydraulic cement mix. The conduit and opening may beas simple as a tube, e.g., a flexible tube with an open end. The conduitmay be sufficiently flexible so as to allow for movement of variouscomponents of the cement mix, e.g., hydraulic cement mixing apparatus,the conduit opening, and the like, and/or sufficiently flexible to beadded to an existing system as a retrofit. On the other hand, theconduit may be sufficiently rigid, or tied-off, or both, to insure thatit does not interfere with any moving part of the cement mix, e.g.,hydraulic cement mixing apparatus. In certain embodiments, part of theconduit can be used for supplying other ingredients to the cement mix,e.g., water, and configured such that either the other ingredient orcarbon dioxide flows through the conduit, e.g., by means of aT-junction.

Carbon dioxide may also be delivered to the cement mix, e.g., hydrauliccement mix as part of the mix water, i.e., dissolved in some or all ofthe mix water. Methods of charging water with carbon dioxide arewell-known, such as the use of technology available in the sodaindustry. Some or all of the carbon dioxide to be used may be deliveredthis way. The mix water may be charged to any desired concentration ofcarbon dioxide achievable with the available technology, such as atleast 1, 2, 4, 6, 8, 10, 12, 14, or 16 g of carbon dioxide/L of water,and/or not more than 2, 4, 6, 8, 10, 12, 14, 18, 20, 22, or 24 g ofcarbon dioxide/L of water, for example 1-12, 2-12, 1-10, 2-10, 4-12,4-10, 6-12, 6-10, 8-12, or 8-10 g of carbon dioxide/L of water. It willbe appreciated that the amount of carbon dioxide dissolved in the mixwater is a function of the pressure of the carbon dioxide and thetemperature of the mix water; at lower temperatures, far more carbondioxide can be dissolved than at higher temperatures. Without beingbound by theory, it is thought that the mix water so charged contactsthe cement mix, e.g., hydraulic cement mix and the carbon dioxidecontained therein reacts very quickly with components of the cement mix,e.g., hydraulic cement mix, leaving the water available to dissolveadditional carbon dioxide that may be added to the system, e.g., ingaseous form.

In certain embodiments, a cement mix such as a concrete mix iscarbonated with carbon dioxide supplied as carbonated water, forexample, in the drum of a ready mix truck. The carbonated water servesas a portion of the total mix water for the particular mix. Thecarbonated water can provide at least 1, 5, 10, 15, 20, 25, 30, 35, 40,50, 60, 70, 80, or 90% of the total mix water, and/or no more than 10,20, 30, 40, 50, 60, 70, 80, 90, 95, or 100% of the mix water. Thecarbonated water may be added at the start of mixing of the cement mix,or it may be added after the start of mixing. It can be added as onebatch or in stages, for example, as 2, 3, 4, 5 or more than 5 batches.The batches may be equal in volume or different volumes, and have thesame carbonation or different carbonations. In certain embodiments, thecarbonated water is less than 100% of the total mix water, for example,less than 80%, or less than 70%, or less than 60%, or less than 50%. Incertain of these embodiments, embodiments, non-carbonated water is firstadded to the mix, and the cement mix, e.g., concrete, is allowed to mixfor a certain period before carbonated water is added, for example, forat least 5, 10, 15, 20, 30, 40, or 50 seconds, or at least 1, 2, 5, 10,15, 20, 25, 30, 40, 50, or 60 minutes before addition of the carbonatedwater, and/or not more than 10, 15, 20, 30, 40, or 50 seconds, or 1, 2,5, 10, 15, 20, 25, 30, 40, 50, 60, 90, 120, 240, or 360 minutes beforeaddition of carbonated water. The carbonated water may contribute all ofthe carbon dioxide used to carbonate a cement mix, e.g., concrete(neglecting atmospheric carbon dioxide); this is especially true forlow-dose carbonation, for example, carbonation with a dose of carbondioxide of less than 1.5% bwc, or less than 1.0% bwc, or less than 0.8%bwc. The carbonated water may contribute part of the carbon dioxide usedto carbonate a cement mix, e.g., concrete, such as not more than 10, 20,30, 40, 50, 60, 70, 80, 90 or 95% of the carbon dioxide and/or at least5, 10, 20, 30, 40, 50, 60, 70, 80, or 90% of the carbon dioxide. Incertain embodiments, the remaining carbon dioxide is supplied as a gas.In certain embodiments, the remaining carbon dioxide is supplied as asolid. In certain embodiments, the remaining carbon dioxide is suppliedas a mixture of a gas and a solid, for example, carbon dioxide deliveredto an orifice directed into the mixer in liquid form, which becomes gasand solid when passing through the orifice. The exact mix of carbonatedwater and other carbon dioxide source will be determined based on thedose of carbon dioxide to be delivered and other factors, such asdelivery time, temperature (lower temperatures allow greater carbondioxide delivery via carbonated water), and the like. The carbonatedwater may be produced by any suitable method, as described herein, andmay be delivered to the mixer, e.g., the ready mix truck, via the normalwater line or via a dedicated line. In certain embodiments carbonatedwater is delivered to the mix at the batch site and/or duringtransportation, and an optional dose is delivered at the job site,depending on the characteristics of the mix measured at the job site.The use of carbonated water can allow for very high efficiencies ofcarbon dioxide uptake, as well as precise control of dosage, so thathighly efficient and reproducible carbon dioxide dosing can be achieved.In certain embodiments in which carbonated mix water is used, theefficiency of carbonation can be greater than 60, 70, 80, 90, or even95%, even when operating in mixers, such as ready mix drums, which areopen to the atmosphere.

Carbon dioxide may be introduced to the mixer such that it contacts thehydraulic cement mix (concrete) before, during, or after addition ofwater, or any combination thereof, so long as it is present during someportion of the mixing of some or all of the cement mix, e.g., hydrauliccement mix. In certain embodiments, the carbon dioxide is introducedduring a certain stage or stages of mixing. In certain embodiments, thecarbon dioxide is introduced to a cement mix, e.g., hydraulic cement mixduring mixing at one stage only. In certain embodiments, the carbondioxide is introduced during one stage of water addition, followed by asecond stage of water addition. In certain embodiments, the carbondioxide is introduced to one portion of cement mix, e.g., hydrauliccement mix, followed by addition of one or more additional portions ofcement mix, e.g., hydraulic cement mix.

In certain embodiments, carbon dioxide is delivered to a flowableconcrete mix, for example, in a mixer, e.g., while the concrete mix ismixing, where the amount of carbon delivered to the concrete mix isdetermined from parameters including pressure and temperaturemeasurements of the carbon dioxide as it is delivered to the concretemix. The carbon dioxide can be delivered, at least in part, as a mixtureof gaseous and solid carbon dioxide produced by exposing liquid carbondioxide to a pressure drop sufficient to induce formation of gaseous andsolid carbon dioxide, for example, by passing liquid carbon dioxidethrough an orifice whose downstream, or distal, end is at atmosphericpressure; a first temperature measurement and a pressure measurement canbe taken of the liquid carbon dioxide on the upstream, or proximal, sideof the orifice and a second temperature measurement can be taken ofcarbon dioxide exiting the orifice, i.e., on the downstream or distalside of the orifice. Apparatus and methods for delivery of the carbondioxide, determining the temperatures and pressure, and determining flowrates and/or amounts of carbon dioxide are as described herein. In theseembodiments, it is not necessary to use other methods of determiningflow and/or total amount of carbon dioxide delivered, such as mass flowcontrollers and/or weights or masses of carbon dioxide containers.

In certain embodiments, a predetermined amount of carbon dioxide isadded to the concrete mix, and the flow of carbon dioxide is halted whenthe amount of carbon dioxide delivered to the mix equals or exceeds thepredetermined amount. In certain embodiments, one or more additionalcharacteristics of the concrete mix or its environment are measured andcarbon dioxide delivery can be modulated based on the amount of carbondioxide delivered in combination with the one or more additionalcharacteristics. The concrete mix can be a wet mix, such as used inready-mix applications and certain wet mix precast operations, or a drymix, such as used in certain dry mix precast operations. The mixer forthe concrete mix can be a stationary mixer, such as a mixer in a precastconcrete operation, or a transportable mixer, such as a drum of aready-mix truck.

The predetermined dose of carbon dioxide may be any suitable dose,generally expressed as a % by weight cement (bwc). In certainembodiments, the dose or amount of carbon dioxide of carbon dioxide thatis determined by the methods and compositions of the invention is0.01-5% bwc, for example, 0.05-4% bwc, in some cases 0.05-2% bwc. Incertain embodiments, a low dose of carbon dioxide is delivered, e.g., anamount less than or equal to 2% bwc, or 1.5% bwc, or 1% bwc. In certainembodiments, the predetermined amount of carbon dioxide to be deliveredto the concrete mix may be not more than 1.5%, 1.2%, 1%, 0.8%, 0.7%,0.6%, 0.5%, 0.4%, 0.3%, 0.2%, 0.1%, or 0.05% bwc and/or at least 0.01,0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, or 1.2% bwc,such as a dose of 0.01-1.5%, 0.01-1.2%, 0.01-1%, 0.01-0.8%, 0.01-0.6%,0.01-0.5%, 0.01-0.4%, 0.01-0.3%, 0.01-0.2%, or 0.01-0.1% bwc, or a doseof 0.02-1.5%, 0.02-1.2%, 0.02-1%, 0.02-0.8%, 0.02-0.6%, 0.02-0.5%,0.02-0.4%, 0.02-0.3%, 0.02-0.2%, or 0.02-0.1% bwc, or a dose of0.04-1.5%, 0.04-1.2%, 0.04-1%, 0.04-0.8%, 0.04-0.6%, 0.04-0.5%,0.04-0.4%, 0.04-0.3%, 0.04-0.2%, or 0.04-0.1% bwc, or a dose of0.06-1.5%, 0.06-1.2%, 0.06-1%, 0.06-0.8%, 0.06-0.6%, 0.06-0.5%,0.06-0.4%, 0.06-0.3%, 0.06-0.2%, or 0.06-0.1% bwc, or a dose of0.1-1.5%, 0.1-1.2%, 0.1-1%, 0.1-0.8%, 0.1-0.6%, 0.1-0.5%, 0.1-0.4%,0.1-0.3%, or 0.1-0.2% bwc. Any other suitable dose, such as thosedescribed throughout U.S. Patent Publication No. 20140373755, or PCTPublication No. WO2014205577, may also be used.

The carbon dioxide, e.g., gaseous carbon dioxide or liquid carbondioxide, is introduced in the mixing cement mix, e.g., hydraulic cementmix, for example, in the first stage of mixing, at a certain flow rateand for a certain duration in order to achieve a total carbon dioxideexposure. The flow rate and duration will depend on, e.g., the purity ofthe carbon dioxide gas, the total batch size for the cement mix, e.g.,hydraulic cement mix and the desired level of carbonation of the mix. Ametering system and adjustable valve or valves in the one or moreconduits may be used to monitor and adjust flow rates. In some cases,the duration of carbon dioxide flow to provide exposure is at or below amaximum time, such as at or below 100, 50, 20, 15, 10, 8, 5, 4, 3, 2, orone minute. In certain embodiments, the duration of carbon dioxide flowis less than or equal to 5 minutes. In certain embodiments, the durationof carbon dioxide flow is less than or equal to 4 minutes. In certainembodiments, the duration of carbon dioxide flow is less than or equalto 3 minutes. In certain embodiments, the duration of carbon dioxideflow is less than or equal to 2 minutes. In certain embodiments, theduration of carbon dioxide flow is less than or equal to 1 minutes. Insome cases, the duration of carbon dioxide flow to provide exposure iswithin a range of times, such as 0.5-20 min, or 0.5-15 min, or 0.5-10min, or 0.5-8 min, or 0.5-5 min, or 0.5-4 min, or 0.5-3 min, or 0.5-2min, or 0.5-1 min, or 1-20 min, or 1-15 min, or 1-10 min, or 1-8 min, or1-5 min, or 1-4 min, or 1-3 min, or 1-2 min. In certain embodiments, theduration of carbon dioxide flow is 0.5-5 min. In certain embodiments,the duration of carbon dioxide flow is 0.5-4 min. In certainembodiments, the duration of carbon dioxide flow is 0.5-3 min. Incertain embodiments, the duration of carbon dioxide flow is 1-5 min. Incertain embodiments, the duration of carbon dioxide flow is 1-4 min. Incertain embodiments, the duration of carbon dioxide flow is 1-3 min. Incertain embodiments, the duration of carbon dioxide flow is 1-2 min.

In low dose carbonation, as in all cement mix, e.g., concrete,carbonation, various factors may be manipulated to produce optimal ordesired results. These include one or more of: time after beginning ofmixing at which carbon dioxide is applied; number of doses of carbondioxide; rate at which carbon dioxide is supplied to the mixing chamber;form of the carbon dioxide (gas, solid, and/or dissolved in water); andthe like. Mixing is said to have commenced upon addition of the firstaliquot of water to the cement-containing mix. It will be appreciatedthat in certain instances, components of a concrete mix, e.g.,aggregate, may be wet and that “the first mix water” may be the water onthe aggregate. Carbon dioxide can be supplied to a mix before the firstaddition of water, for example by flooding a chamber or head space withcarbon dioxide before water addition, but in this case the applicationof carbon dioxide is considered to occur when the first water is added,since virtually no reaction will occur until the carbon dioxidedissolves in the mix water. Thus, in certain embodiments, carbon dioxideis applied to the mix at 0 minutes, that is, carbon dioxide is presentto the mix chamber when the first mix water is supplied, or supplyingcarbon dioxide to the mix chamber commences when the first mix water isapplied, or both. In certain embodiments, carbon dioxide is applied atleast 1, 2, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, or 90 minutes aftermixing commences, and/or not more than 2, 5, 10, 15, 20, 30, 40, 50, 60,70, 80, 90, 120, or 180 minutes after mixing commences. For example, inthe case of carbon dioxide supplied to a concrete mix in a ready mixtruck, the mix components, including at least part of the mix water, maybe added to the truck, and it may be desirable that carbon dioxideaddition not commence until at least 2, 3 or 4 minutes or more aftermixing has commenced. Such addition could occur, e.g., at a washstation, where the driver stops to wash the truck before commencingdelivery; the truck is usually stopped at the wash station for at least5-10 minutes, and an on-site carbon dioxide delivery system can be usedto supply carbon dioxide to the drum of the truck during the washstation stop. Part or all of the dose of carbon dioxide can be deliveredin this manner, for example by delivering carbon dioxide to the truckthrough the water line (though any suitable means may be used); inembodiments where a carbon dioxide source is attached to the truck theremay be some mechanism to remind the driver to detach it beforedeparting, such as an alarm. Alternatively, or additionally, thedesirable time for addition of carbon dioxide to the mix may be later inthe mix time, such as at a time that the truck is normally en route tothe job site, or at the job site. In this case, a portable source ofcarbon dioxide may be attached to the truck, with suitable valving andtubing, so as to deliver one or more doses of carbon dioxide to the drumof the truck at a later time, such as at least 15, 30, or 60 minutesafter mixing commences. A controller, which may be self-contained or maybe remotely activated and which may send signals to a remote siteregarding dosing and other information, may be included in the system sothat dosing commences at a predetermined time after mixing commences andcontinues for a predetermined time, or continues until somepredetermined characteristic or characteristics of the concrete mix isdetected. Alternatively, the time and/or duration of dosing may bemanually controlled, or subject to manual override. The carbon dioxidesource can be as simple as a pressurized tank of gaseous carbon dioxide,which can be topped off periodically, for example when the truck returnsto the batching site, to ensure a sufficient supply of carbon dioxidefor any ensuing round of carbonation, e.g., without the need toascertain carbon dioxide levels in the tank. In these embodiments, someor all of the carbonation may occur at the job site, for example, basedon determination of one or more characteristics of the concrete.

The rate of delivery of the carbon dioxide may be any desired rate andthe rate may be controlled by any suitable means. A slower rate ofdelivery may be desired, especially in wet mix operations such as readymix operations, where the higher w/c ratio is known to slow carbonationcompared to lower w/c operations, e.g., some precast operations. Thus,although a single dose may be used, in some cases the total dose ofcarbon dioxide is divided into two or more smaller doses. Thus, thecarbon dioxide may be delivered as a single dose, or as multiple doses,for example, as at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 doses, and/or notmore than 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, or 20 doses; such as 2-10doses, or 2-5 doses. Each dose may be equal in size to the others ordifferent, and the interval between doses may be timed equally or not,as desired. The exact number and size of the doses may be predetermined,or it may be dictated by one or more characteristics of the mix that aremonitored. The carbon dioxide may be in any suitable form, such as gas,or a gas/solid mix. Any other suitable division of doses, such as thosedescribed throughout U.S. Patent Publication No. 20140373755, or PCTPublication No. WO2014205577 may also be used.

The dose chosen for a given mix, for example, to produce a desiredincrease in early strength or set, or to produce an optimal increase inearly strength or set, can be dependent on the mix and especially on thecement used in the mix. In certain embodiments the invention provides amethod of carbonating a cement mix, e.g., concrete, during mixing, wherecarbon dioxide is added to the mix at a predetermined dose, where thepredetermined dose is determined by testing one or more components ofthe mix, for example, the concrete, to determine a dose or a range ofdoses that produces optimal or desired increase in early strength and/orset. It will be appreciated that, in the case of low dose carbonation, acarbonation value may not be able to be determined, and that strengthtests can require multiple samples and days to weeks to complete. Thusin some embodiments, a predetermined dose of carbon dioxide isdetermined using an alternative marker, such as isothermal calorimetry.Heat release during hydration is related to two somewhat overlappingpeaks. The main heat release is related to the hydration of silicates,while a second heat release, observed as a hump on the downslope of thesilicate peak, is associated with the hydration of the aluminates.Isothermal calorimetry testing is easy to carry out in mortar or evencement paste with very minimal sample preparation compared to the makingof concrete samples, thus allowing for a rapid and convenient method ofdetermining an optimal CO₂ dose and timing for a given cement, bytesting a range of doses and delivery times. The results obtained areeither in the form of heat flow rate over time (also referred to aspower vs. time herein), which describes the rate of cement hydration, orin the form of heat of hydration over time, which is the integrated heatflow rate (also referred to as energy vs. time herein).

The methods and compositions of the invention allow for very high levelsof efficiency of uptake of carbon dioxide into the mixing concrete,where the efficiency of uptake is the ratio of carbon dioxide thatremains in the mixing concrete as stable reaction products to the totalamount of carbon dioxide to which the mixing concrete is exposed. Incertain embodiments, the efficiency of carbon dioxide uptake, forexample, in ready mix trucks at full capacity during a period ofoperation at a batching plant, such as averaged over all trucksreceiving carbon dioxide in a single day, is at least 40, 50, 60, 70,80, 90, 95, 96, 97, 98, 99, or 99%, or 40-100, 50-100, 60-100, 70-100,80-100, 90-100, 40-99, 50-99, 60-99, 70-99, 80-99, or 90-99%. This isespecially true in open mixers, e.g., the drum of a ready mix truck;such efficiencies may be achieved by the positioning of the conduit todeliver carbon to the mixing concrete in the drum of the truck, othercharacteristics of the methods and compositions of the inventiondescribed herein, or a combination thereof.

Part of an apparatus of the invention can be, for example a firstcontroller, e.g., a first PLC, that controls the carbon dioxidedelivery, which may receive one or more signals from the mix operationand/or one or more signals from a second controller, for example asecond PLC, for the mix system, or both, that indicates a change in anaspect of the mix operation is occurring. The signal or signals may beused, e.g., to time the initiation of carbon dioxide delivery. Inembodiments in which a predetermined amount of carbon dioxide is to bedelivered, the amount of carbon dioxide delivered is then determinedfrom the time that delivery starts from parameters including, e.g.,pressure and temperature measurements for the carbon dioxide asdescribed herein, and is halted when the predetermined amount isreached.

For example, in a stationary mixer system, the first controller mayreceive a signal from the proximity switch or the customer PLCindicating cement gate opening. This signal may be used to time theinitiation of carbon dioxide delivery. In embodiments where apredetermined amount of carbon dioxide is to be added to the concretemix, flow rate and total amount of carbon dioxide delivered can bedetermined as described herein, until the predetermined amount of carbondioxide is reached and the first controller causes carbon dioxidedelivery to cease.

An alternative method may be used, for example, when a predeterminedamount of carbon dioxide is to be delivered to a transportable mixer,such as the drum of a ready-mix truck. Instead of getting a signal fromthe proximity switch or the customer PLC indicating cement gate opening,the first controller, e.g., PLC, receives a signal, e.g., a 120 VACsignal, from the ready-mix batching system indicating that carbondioxide delivery to the drum of the truck is to be initiated. The signalis continuous as long as carbon dioxide delivery is to continue, andcarbon dioxide delivery stops when the signal is lost.

The first controller determines flow rate and amount carbon dioxidedelivered, and outputs a signal, e.g., a 24 VDC pulse for everyincremental amount of CO₂ delivered, for example, for every x kg of CO₂delivered to a drum of a ready-mix truck. The ready-mix batching systemcounts the number of pulses and stops the 120 VAC signal once it reachesthe desired number of pulses that corresponds to the desired dose ofCO₂, thus ending CO₂ delivery to the truck. The result is that thesystem can deliver, e.g., full liquid at maximum flow to the orificewithout having to turn the valve off and on. During the operation of theliquid system the gas and liquid valves can be opened and closed tomaintain a set average flow rate over a given amount of time. In thiscase, once the liquid valve is opened, it remains open until the desireddose (mass) has been achieved, then shuts off using the normal valvesequence as outlined herein. This procedure simplifies carbon dioxidedelivery because flow is determined by the equations above, with just afew measurements needed. There is also no need for recipes in the firstcontroller, since dosing information can be drawn from the ready-mixbatching system controller, e.g., PLC. A light may be added thatilluminates when carbon dioxide delivery is occurring. One or moresensors in the vicinity of the drum can be used to monitor carbondioxide concentrations for safety purposes and carbon dioxide deliverycan be halted if a threshold is exceeded; an alarm can also bedelivered, such as an alarm sound, or light, or both.

The dosing may be started at any suitable time before, during, or afterthe mixing of the concrete begins, that is, after water is added so thatthe cement in the concrete mix begins hydration, for example,immediately upon addition of water, or after at least 10, 20, 30, 40, or50 seconds, or at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, or 20minutes after addition of water.

One or more admixtures may also be added to the concrete mix, before,during, and/or after the addition of the carbon dioxide. In certaincases, the addition of carbon dioxide alters the properties of theconcrete mix in such a manner that it is desirable to add an admixtureto the mix to counteract the effect of the carbon dioxide; for example,in certain cases, addition of carbon dioxide can reduce the flowabilityof the concrete mix and it is desirable to add an admixture that returnsflowability to a desired level. In certain embodiments, one or moreadmixtures, described more fully below, are added at a time and in aconcentration so that flowability of the final concrete mix is within50, 40, 30, 20 15, 10, 8, 5, 4, 3, 2, or 1% of the flowability thatwould be achieved without the addition of carbon dioxide, or of apredetermined flowability. In certain embodiments, one or moreadmixtures, described more fully below, are added at a time and in aconcentration so that flowability of the final concrete mix is within20% of the flowability that would be achieved without the addition ofcarbon dioxide, or a predetermined flowability. In certain embodiments,one or more admixtures, described more fully below, are added at a timeand in a concentration so that flowability of the final concrete mix iswithin 10% of the flowability that would be achieved without theaddition of carbon dioxide, or a predetermined flowability. In certainembodiments, one or more admixtures, described more fully below, areadded at a time and in a concentration so that flowability of the finalconcrete mix is within 5% of the flowability that would be achievedwithout the addition of carbon dioxide, or a predetermined flowability.In certain embodiments, one or more admixtures, described more fullybelow, are added at a time and in a concentration so that flowability ofthe final concrete mix is within 2% of the flowability that would beachieved without the addition of carbon dioxide, or a predeterminedflowability. In certain embodiments, one or more admixtures, describedmore fully below, are added at a time and in a concentration so thatflowability of the final concrete mix is within 1-50%, or 1-20%, or1-10%, or 1-5%, or 2-50%, or 2-20%, or 2-10%, or 2-5% of the flowabilitythat would be achieved without the addition of carbon dioxide, or apredetermined flowability. Any suitable measurement method fordetermining flowability may be used, such as the well-known slump test.

If one or more admixtures is used, any suitable admixture may be used,such as those described in U.S. Patent Publication No. 20140373755, orPCT Publication No. WO2014205577. In particular, useful admixturesinclude set retarders. Set retarders include carbohydrates, i.e.,saccharides, such as sugars, e.g., fructose, glucose, and sucrose, andsugar acids/bases and their salts, such as sodium gluconate and sodiumglucoheptonate; phosphonates, such as nitrilotri(methylphosphonic acid),2-phosphonobutane-1,2,4-tricarboxylic acid; and chelating agents, suchas EDTA, Citric Acid, and nitrilotriacetic acid. Other saccharides andsaccharide-containing admixes of use in the invention include molassesand corn syrup. In certain embodiments, the admixture is sodiumgluconate. Other exemplary admixtures that can be of use as setretarders include sodium sulfate, citric acid, BASF Pozzolith XR, firmedsilica, colloidal silica, hydroxyethyl cellulose, hydroxypropylcellulose, fly ash (as defined in ASTM C618), mineral oils (such aslight naphthenic), hectorite clay, polyoxyalkylenes, natural gums, ormixtures thereof, polycarboxylate superplasticizers, naphthalene HRWR(high range water reducer). Additional set retarders that can be usedinclude, but are not limited to an oxy-boron compound, lignin, apolyphosphonic acid, a carboxylic acid, a hydroxycarboxylic acid,polycarboxylic acid, hydroxylated carboxylic acid, such as fumaric,itaconic, malonic, borax, gluconic, and tartaric acid, lignosulfonates,ascorbic acid, isoascorbic acid, sulphonic acid-acrylic acid copolymer,and their corresponding salts, polyhydroxysilane, polyacrylamide.Illustrative examples of retarders are set forth in U.S. Pat. Nos.5,427,617 and 5,203,919. The admixture or admixtures may be added to anysuitable final percentage (bwc), in some cases, the concentration isgreater than 0.01%, 0.015%, 0.02%, 0.025%, 0.03%, 0.035%, 0.04%, 0.05%,0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.15%, 0.2%, 0.3%, 0.4%, or 0.5% bwc.The concentration may also be less than 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6,0.5, 0.4, 0.3, 0.2, or 0.1%. For example, a suitable range of dose, bwc,may be used, such as in the range of 0.01-0.5%, or 0.01-0.3%, or0.01-0.2%, or 0.01-0.1%, or 0.01-1.0%, or 0.01-0.05%, or 0.05% to 5%, or0.05% to 1%, or 0.05% to 0.5%, or 0.1% to 1%, or 0.1% to 0.8%, or 0.1%to 0.7% per weight of cement. The admixture may be added to a finalpercentage of greater than 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07,0.08, 0.09, 0.1, 0.15, 0.2, 0.3, 0.4, or 0.5%; in certain cases alsoless than 5, 4, 3, 2, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1,0.09, 0.08, 0.07, 0.06, 0.05, 0.04, 0.03, or 0.02%. For example, incertain embodiments, sodium gluconate is used as an admixture at a doseof between 0.01 and 1% bwc, or between 0.01 and 0.8%, or between 0.01and 0.5%, or between 0.01 and 0.4% bwc, or between 0.01 and 0.3%, orbetween 0.01 and 0.2% bwc, or between 0.01 and 0.1%, or between 0.01 and0.05%, or between 0.03 and 1% bwc, or between 0.03 and 0.8%, or between0.03 and 0.5%, or between 0.03 and 0.4% bwc, or between 0.03 and 0.3%,or between 0.03 and 0.2% bwc, or between 0.03 and 0.1%, or between 0.03and 0.08%, or between 0.05 and 1% bwc, or between 0.05 and 0.8%, orbetween 0.05 and 0.5%, or between 0.05 and 0.4% bwc, or between 0.05 and0.3%, or between 0.05 and 0.2% bwc, or between 0.05 and 0.1%, or between0.05 and 0.08%, or between 0.1 and 1% bwc, or between 0.1 and 0.8%, orbetween 0.1 and 0.5%, or between 0.1 and 0.4% bwc, or between 0.1 and0.3%, or between 0.1 and 0.2% bwc. The sodium gluconate may be addedbefore, during, or after carbonation of the mix, or any combinationthereof, and may be added as one, two, three, four, or more than fourdivided doses. The carbohydrate or derivative may be added in two ormore doses, such as one dose before carbonation and one dose duringand/or after carbonation. In certain embodiments, calcium stearate isused as an admixture.

In certain embodiments, a second admixture is also used, such as any ofthe admixtures described in U.S. Patent Publication No. 20140373755, orPCT Publication No. WO2014205577. In certain embodiments, the secondadmixture is a strength accelerator. In certain embodiments, a thirdadmixture is also used, such as any of the admixtures described in U.S.Patent Publication No. 20140373755, or PCT Publication No. WO2014205577.In certain embodiments, a fourth admixture is also used, such as any ofthe admixtures described in U.S. Patent Publication No. 20140373755, orPCT Publication No. WO2014205577. See, e.g., paragraphs 88-105, 183,Table 1, and Examples and Figures of U.S. Patent Publication No.20140373755.

In certain embodiments, one or more supplementary cementitious materials(SCMs) and/or cement replacements are added to the mix at theappropriate stage for the particular SCM or cement replacement. Incertain embodiments, an SCM is used. Any suitable SCM or cementreplacement may be used; exemplary SCMs include blast furnace slag, flyash, silica fume, natural pozzolans (such as metakaolin, calcined shale,calcined clay, volcanic glass, zeolitic trass or tuffs, rice husk ash,diatomaceous earth, and calcined shale), and waste glass. Further cementreplacements include interground limestone, recycled/waste plastic,scrap tires, municipal solid waste ash, wood ash, cement kiln dust,foundry sand, and the like. In certain embodiments, an SCM and/or cementreplacement is added to the mix in an amount to provide 0.1-50%, or1-50%, or 5-50%, or 10-50%, or 20-50%, or 1-40%, or 5-40%, or 10-50%, or20-40% bwc. In certain embodiments, an SCM is used and the SCM is flyash, slag, silica fume, or a natural pozzolan. In certain embodiment,the SCM is fly ash. In certain embodiments, the SCM is slag.

It is well-known that addition of an SCM such as fly ash or slag to acement mix, e.g., concrete mix, can retard early strength development;indeed, when weather becomes cold enough, the use of SCM in mixes iscurtailed because the early strength development is sufficientlyretarded as to make the use of the mix problematic. In addition, themaximum amount of SCM that may be added to a mix can be limited by itseffect on early strength development. The present inventors have foundthat even very low doses of carbon dioxide, when added to a concrete mixcontaining SCM, can accelerate early strength development and thus couldallow such mixes to be used under circumstances where they otherwisemight not be used, e.g., in cold weather, or in greater amounts, thusextending the usefulness of such mixes, such as extending the usefulseason for such mixes, or increasing the proportion of SCM in a givenmix, or both.

In certain embodiments the invention provides methods and compositionsfor the expanding the range of conditions under which an SCM may be usedin a concrete mix by carbonating the mix. The range of conditions mayinclude the temperature at which the SCM-containing mix may be used, orthe amount of SCM that may be added while maintaining adequate earlystrength development, or the early strength for a given amount of SCM ina mix.

In certain embodiments, the invention provides a method for decreasingthe minimum temperature at which an SCM-concrete mix may be used, thusincreasing the overall acceptable temperature range for the SCM-concretemix, by exposing the SCM-concrete mix to a dose of carbon dioxidesufficient to modulate, e.g., accelerate, early strength developmentand/or set of the mix to a level at which the mix may be used at atemperature below that at which it could have been used without thecarbon dioxide exposure. The dose can be such that the early strengthdevelopment of the mix allows its use in a desired manner at atemperature that is at least 1, 2, 3, 4, 5, 6, 8, 9, or 10° C. below thetemperature at which it could be used without the carbon dioxidetreatment and/or not more than 2, 3, 4, 5, 6, 8, 9, 10, or 12° C. belowthe temperature at which it could be used without the carbon dioxidetreatment. The dose of carbon dioxide added to the mix to achieve thedesired increase in early strength development can be not more than 2.0,1.5, 1.2, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, or 0.05%carbon dioxide bwc. The dose can be such that the early strengthdevelopment of the mix, e.g., the strength at 8, 12, 16, 20, or 24hours, or any other suitable time point for early strength development,is, on average, at least 1, 2, 5, 7, 10, 12, 15, 20, or 25% greater thanthe strength without the carbon dioxide dose, and is sufficient for theuse for which the mix is intended. In certain embodiments, analternative or additional marker other than early strength development,such as a value from calorimetry as described elsewhere herein, may beused instead of or in addition to early strength measurements, forexample, to determine the desired or optimal dose of carbon dioxideand/or dosing conditions. The carbon dioxide may be delivered as asingle dose or multiple doses, and at any suitable rate or in anysuitable form, as described elsewhere herein. The SCM can be anysuitable SCM. In certain embodiments, the SCM is fly ash. In certainembodiments, the SCM is slag. In certain embodiments, the SCM-concretemix is delivered to a job site in a ready mix truck, and the carbondioxide is applied to the mix at the batching site, en route to the jobsite, or at the job site, or any combination thereof. In certainembodiments, the carbon dioxide is gaseous carbon dioxide. In certainembodiments, the carbon dioxide is dissolved in mix water. In certainembodiments, the carbon dioxide is solid carbon dioxide. In certainembodiments, a combination of gaseous carbon dioxide and carbon dioxidedissolved in mix water is used.

In certain embodiments, the invention provides a method for increasingthe maximum amount (proportion) of SCM that may be used in anSCM-concrete mix, thus increasing the overall acceptable range ofamounts (proportions) of SCM for the SCM-concrete mix, by exposing anSCM-concrete mix that contains a proportion of SCM that would normallybe higher than the acceptable proportion due to effects on earlystrength development, to a dose of carbon dioxide sufficient tomodulate, e.g., accelerate, early strength development of the mix to alevel at which the mix may be used for its normal purposes. In certainembodiments, the maximum acceptable proportion of SCM in the mix isincreased by carbonation by at least 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 5,6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20% bwc and/ornot more than 1, 1.5, 2, 2.5, 3, 3.5, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,14, 15, 16, 17, 18, 19, 20, or 25% bwc, over the maximum acceptableproportion of SCM without carbonation. The dose of carbon dioxide to themix can be not more than 2.0, 1.5, 1.2, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5,0.4, 0.3, 0.2, 0.1, or 0.05% carbon dioxide bwc, and/or not less than 25, 2.0, 1.5, 1.2, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1%carbon dioxide bwc. The SCM can comprises at least 1, 2, 3, 4, 5, 6, 7,8, 9, 10, 12, 15, 20, or 30% of the mix, and/or not less than 2, 3, 4,5, 6, 7, 8, 9, 10, 12, 15, 20, 30, 40, or 50% of the mix. The dose canbe such that the early strength development of the mix, e.g., thestrength at 8, 12, 16, 20, or 24 hours, or any other suitable time pointfor early strength development, is, on average, at least 1, 2, 5, 7, 10,12, 15, 20, or 25% greater than the strength without the carbon dioxidedose. In certain embodiments, an alternative or additional marker otherthan early strength development, such as a value from calorimetry asdescribed elsewhere herein, may be used instead of or in addition toearly strength measurements, for example, to determine the desired oroptimal dose of carbon dioxide and/or dosing conditions. The carbondioxide may be delivered as a single dose or multiple doses, and at anysuitable rate or in any suitable form, as described elsewhere herein.The SCM can be any suitable SCM. In certain embodiments, the SCM is flyash. In certain embodiments, the SCM is slag. In certain embodiments,the SCM-concrete mix is delivered to a job site in a ready mix truck,and the carbon dioxide is applied to the mix at the batching site, enroute to the job site, or at the job site, or any combination thereof.In certain embodiments, the carbon dioxide is gaseous carbon dioxide. Incertain embodiments, the carbon dioxide is dissolved in mix water. Incertain embodiments, the carbon dioxide is solid carbon dioxide. Incertain embodiments, a combination of gaseous carbon dioxide and carbondioxide dissolved in mix water is used.

In certain embodiments, the invention provides a method for acceleratingthe early strength development of an SCM-concrete mix, thus acceleratingaspects of a job in which the SCM-concrete mix is used that require acertain strength before a next step may be taken (such as removingmolds, adding a level of concrete, and the like), by exposing theSCM-concrete mix to a dose of carbon dioxide sufficient to modulate,e.g., accelerate, early strength development of the mix to a level atwhich the aspect of the job may be accelerated. The dose of carbondioxide to the mix can be not more than 2.0, 1.5, 1.2, 1.0, 0.9, 0.8,0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, or 0.05% carbon dioxide bwc, and/ornot less than 2.5, 2.0, 1.5, 1.2, 1.0, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4,0.3, 0.2, or 0.1% carbon dioxide bwc. The dose can be such that theearly strength development of the mix, e.g., the strength at 8, 12, 16,20, or 24 hours, or any other suitable time point for early strengthdevelopment, is, on average, at least 1, 2, 5, 7, 10, 12, 15, 20, 25,30, 35, or 40% greater than the strength without the carbon dioxidedose. The SCM can comprises at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 12,15, 20, or 30% of the mix, and/or not less than 2, 3, 4, 5, 6, 7, 8, 9,10, 12, 15, 20, 30, 40, or 50% of the mix. In certain embodiments, analternative or additional marker than early strength development, suchas a value from calorimetry as described elsewhere herein, may be usedinstead of or in addition to early strength measurements, for example,to determine the desired or optimal dose of carbon dioxide and/or dosingconditions. The carbon dioxide may be delivered as a single dose ormultiple doses, and at any suitable rate or in any suitable form, asdescribed elsewhere herein. The SCM can be any suitable SCM. In certainembodiments, the SCM is fly ash. In certain embodiments, the SCM isslag. In certain embodiments, the SCM-concrete mix is delivered to a jobsite in a ready mix truck, and the carbon dioxide is applied to the mixat the batching site, en route to the job site, or at the job site, orany combination thereof. In certain embodiments, the carbon dioxide isgaseous carbon dioxide. In certain embodiments, the carbon dioxide isdissolved in mix water. In certain embodiments, the carbon dioxide issolid carbon dioxide. In certain embodiments, a combination of gaseouscarbon dioxide and carbon dioxide dissolved in mix water is used.

In a ready-mix operation, the carbon dioxide may be delivered to thedrum of the truck via a conduit, or lance or wand, that is positionedrelative to the drum of each truck as it passes through the deliverysite, e.g., the batching site, a wash station, or other suitable carbondioxide delivery site. The lance can attached to the orifice asdescribed herein, for example, at a NPT connection as shown in FIG. 1 ,and used to direct the carbon dioxide, such as mixture of solid andgaseous carbon dioxide, to a desired location in the drum. The lance ispositioned so that carbon dioxide is delivered to the concrete mix inthe drum of the truck. When carbon dioxide delivery is complete, thelance is moved as necessary to allow the truck to leave the deliverysite and a new truck to enter the delivery site, then positioned asnecessary for the next carbon dioxide delivery to the new truck. Ingeneral, it is preferable that the lance or wand be constructed ofinsulating materials so as to preserve the carbon dioxide in solid formand minimize sublimation to gaseous carbon dioxide, which improvesefficiency of delivery of the carbon dioxide to the concrete mix.

When such a delivery system is used, the positioning of the conduit forthe carbon dioxide so that the opening is in a certain position andattitude relative to the drum can be important; one aspect of someembodiments of the invention is positioning the wand, and/or anapparatus for doing so, to facilitate efficient mixing of the gaseousand/or solid carbon dioxide with the cement mix as the drum rotates. Anysuitable positioning method and/or apparatus may be used to optimize theefficiency of uptake of carbon dioxide into the mixing cement as long asit positions the wand in a manner that provides efficient uptake of thecarbon dioxide, for example, by positioning the wand so that the openingis directed to a point where a wave of concrete created by fins of aready-mix drum folds over onto the mix; without being bound by theory itis thought that the wave folding over the fin immediately subsumes thecarbon dioxide, e.g., solid carbon dioxide within the cement mix so thatit releases gaseous carbon dioxide by sublimation into the mix ratherthan into the air, as it would do if on the surface of the mix. Oneexemplary positioning is shown in FIG. 5 , where the wand is aimed atthe second fin in the drum of the truck, on the bottom side of the fin.In a ready-mix truck carrying a full load, the opening of the wand maybe very close to the surface of the mixing concrete, as described below,to facilitate the directional flow of the carbon dioxide mix into theproper area. Part or all of the wand may be made of flexible material sothat if a fin or other part of the drum hits the wand it flexes thenreturns to its original position.

In certain embodiments, the invention provides a system for positioninga carbon dioxide delivery conduit on a ready-mix truck so that theopening of the conduit is directed to a certain position in the drum ofthe truck, for example, as described above. The conduit may delivergaseous carbon dioxide or a mixture of gaseous and solid carbon dioxidethrough the opening. In the latter case, the conduit is constructed ofmaterials that can withstand the liquid carbon dioxide carried by theconduit to the opening. The system can include a guide, which may bemounted on the truck, for example permanently mounted, that isconfigured to allow the reversible attachment and positioning of theconduit, for example, by providing a cylinder or holster into which theconduit can be inserted, so that the conduit is positioned at thedesired angle for delivery of the carbon dioxide to a particular point,and a stop to ensure that the conduit is inserted so that the opening isat the desired distance from the concrete. This is merely exemplary andone of skill in the art will recognize that any number of reversibleattachment and positioning devices may be used, so long as the angle andposition of the opening relative to a desired point in the drum isobtained, e.g., clamps, etc. The wand is positioned in the guide, forexample, manually by the driver of the ready-mix truck, or automaticallyby an automated system that senses the positions of the variouscomponents, or a combination thereof. When the wand is properlypositioned, a signal is sent to a control system alerting the systemthat the wand is in position. The signal may be sent manually, e.g., bythe driver of the truck after insertion of the wand, or by a batcher, oranother operator, e.g., by pressing a button. Alternatively, a sensormay be tripped when the wand is positioned properly. Once the systemcontroller is alerted that the wand is in position, carbon dioxidedelivery can begin, either at that time or after a desired delay. Thecontroller can be configured so that if the conduit is not positionedproperly, e.g., the operator or sensor does not send the signal, thedelivery will not start. The system may also be configured so that ifone or more events occur during before, during, or after delivery, analarm sounds and/or delivery is modulated, for example, stopped, or notinitiated. For example, an alarm can sound if the wand loses signal fromthe positioning sensor during injection, or the pressure exceeds acertain threshold, e.g., the pressure is greater than 25 psi when bothvalves for delivery of gaseous and liquid carbon dioxide to the conduitis closed, e.g., when both are closed (which determines if a valvesticks open), or if the next truck in the queue has not been initiatedin a certain amount of time. Exemplary logic for a controller caninclude:

If the wand loses signal during injection, an alarm light can come onand a message can pop on a HMI, for example, a screen, informing anoperator that the injection wand is disconnected and to reconnect andpress Start button to continue. There can also be an indicator, e.g., abutton that indicates “Injection Complete” which would end that batchand record what was actually injected vs the target. In a batchingfacility in which a plurality of different trucks are being batched, asystem controller may be configured to receive input regarding theidentity of each truck at the carbon dioxide delivery site and selectthe appropriate action, e.g., delivery/no delivery, timing, flow, andamount of carbon dioxide delivered, and the like. For example, forentering a truck number that corresponds to the current truck beingbatched (signal being sent to plc), a dialog box can pop up when thesystem controller gets the signal from the customer PLC asking anoperator to “Please input Identification Number” (e.g., a 1-10 digitnumber), alternatively, the truck identifier numbers can be in apredetermined order, e.g., sequential. To choose the option, there maybe a selector switch on the maintenance screen. Feedback may also beprovided to an operator, e.g., a batcher, showing relevant informationfor the batches run, such as Identification Number, Time Batched, TimeInjected, Dose Required and Dose Injected, and the like. The units ofthe dose can be any suitable units, for example either lbs or kgsdepending on the units selected. A “spreadsheet” can be provided thatshows all batches from the current day (or makes the date selectable) sothat the batcher can review it and scroll though, for example aprintable spreadsheet.

Thus, for example, a carbon dioxide delivery system may be positioned ata ready-mix facility at a point where trucks stop for sufficient timefor delivery of the desired dose of carbon dioxide to the drum of thetruck, for example, at a wash rack. The carbon dioxide delivery systemmay be one that delivers a mixture of solid and gaseous carbon dioxidethrough an orifice, as described herein. The orifice may be operablyconnected to a conduit, such as a flexible conduit, that leads thecarbon dioxide, e.g., a mixture of gaseous and solid carbon dioxide, toa wand that then delivers the carbon dioxide to the drum of theready-mix truck. The flexible conduit is of sufficient length to allowfor flow of carbon dioxide from the source of carbon dioxide to the wandwhen the wand is positioned at the desired position in the ready-mixtruck, e.g., 5-30 feet in length, such as 10-25 feet in length, or anyother suitable length according to the particular setup. The flexibleconduit is generally constructed of insulating material, for example, avacuum jacketed hose, that can withstand the temperatures of the mixtureof gaseous and solid carbon dioxide. Any suitable diameter of hose maybe used, for example, ¼-1 inch, or ¼-¾ inch, or about ½ inch diameter.

The flexible conduit can be operably connected to a wand, which, ingeneral, is a rigid or semi-rigid conduit so that it can be reliably andreproducibly positioned to deliver the carbon dioxide to a desiredlocation in a mixer, such as a drum of a ready-mix truck; in general theconduit will also include a handle that is insulated for ease ofhandling and for positioning the wand in a holder, e.g., a holster, onor near the drum of the ready-mix truck. The wand can be constructed ofany suitable material or combination of materials, that is, e.g.,material that can withstand the temperatures of the mixture of solid andgaseous carbon dioxide that pass through it. In certain embodiments,part or all of the wand comprises an inner aluminum tube and an outerrigid plastic tube; the aluminum tube may extend all of the way throughthe outer plastic tube or only part way. The outer pipe may be anysuitable material, such as polyvinyl chloride (PVC) or acrylonitrilebutadiene styrene (ABS). In certain embodiments, the aluminum tubeextends only to the end of the handle, and the rest of the wand isplastic pipe. In certain embodiments, the wand is entirely constructedof the plastic pipe. These materials are merely exemplary and it will beappreciated that any material that imparts the necessary rigidity fordirecting the flow of carbon dioxide to the desired spot and thenecessary robustness to withstand the temperatures and workingconditions may be used. The length of the wand may be any suitablelength that allows for ease of handling and for correct positioning; incertain embodiments the wand is 3-8 feet long, such as 3-7 feet long, or3-6 feet long.

The wand preferably includes a handle or stop, which is of greaterdiameter than the rest of the wand and which is shaped to fit into aholder, e.g., a holster, that is attached to or near the drum of theready-mix truck, e.g., at the hopper. The holder, e.g., holster, isattached to or near the drum of the ready-mix truck in such a positionthat the wand may be inserted into or attached to it, e.g., by the truckoperator, and, once inserted, reliably and reproducibly directs carbondioxide to the desired location in the drum of the truck. In general,the location is chosen to deliver carbon dioxide to a spot in a fulltruck that will cause the carbon dioxide to be subsumed into the mixingconcrete in an efficient manner, as described herein. The handle or stopcan be configured so as to lock the wand into place once inserted. Asdescribed elsewhere herein, the assembly may include a sensor, e.g., onthe locking mechanism, to alert a controller system that the wand hasbeen properly positioned; alternatively, an operator may manually alertthe system that the wand is properly positioned, e.g., by pressing abutton. The wand may also include, at the distal end, a flexible portionso that it can be contacted by the concrete truck fins or concretewithout damage. In addition, the wand may be scored, e.g., at the pointwhere the wand leaves the hopper and enters the truck so that if it getscaught and enough force is exerted upon it, it will break away withoutdamaging the upper part of the wand. The wand may also have a hosebreakaway in case the truck drives away without removing the wand. Thisbreakaway can also sever a sensor wire, if included, telling the systemthat the wand is no longer locked in place and thus stopping flow if ithas not already been stopped.

FIG. 6 shows one example of a wand and holder.

Certain embodiments of the invention provide a positioning system forpositioning a carbon dioxide delivery conduit in a drum of a ready-mixtruck, wherein the positioning system is attached to the ready-mixtruck, for example, at or near the drum of the ready-mix truck, andincludes a holder into which the conduit can be positioned so that theopening of the conduit is in a desired location for delivery of carbondioxide to the concrete of the ready-mix truck. The holder is attachedto the truck, e.g., by welding or bolting or other suitable attachmentmethod to provide a reliable attachment to the truck. The system mayinclude a reversible locking mechanism for locking the conduit in placeonce it is inserted. The system thus may be, e.g., a holster asdescribed herein, and include a reversible locking mechanism for lockingthe conduit in place once it is inserted. Thus, in an operation thatincludes a plurality of ready-mix trucks, for any truck for which carbondioxide delivery is desired, a positioning system is affixed to thetruck in a suitable location; each truck has its own positioning systemthat travels with the truck and is used, in combination with the wandand the carbon dioxide delivery and control system, when carbon dioxidedelivery to a load of concrete is desired.

In embodiments in which carbon dioxide is contacted with the surface ofthe cement mix, e.g., hydraulic cement mix such as concrete, such asmixing concrete in a drum of a ready-mix truck, the flow of carbondioxide may be directed from an opening or plurality of openings (e.g.,conduit opening) that is at least 5, 10, 20, 30, 40, 50, 60, 70, 80, 90,or 100 cm from the surface of the cement mix, e.g., hydraulic cement mixduring carbon dioxide flow, on average, given that the surface of themix will move with mixing, and/or not more than 10, 20, 30, 40, 50, 60,70, 80, 90, 100, 120, 140, 170, or 200 cm from the surface of the cementmix, e.g., hydraulic cement mix during carbon dioxide flow, on average.In certain embodiments, the opening is 5-100 cm from the surface, onaverage, such as 5-60 cm, for example 5-40 cm. In certain embodiments,the opening is 10-100 cm from the surface, on average, such as 10-60 cm,for example 10-40 cm. When the mixer is a drum of a ready-mix truck,these distances are generally calculated for a full load in the drum.

Thus, certain embodiments of the invention provide apparatus and methodsfor delivering carbon dioxide, e.g., a mixture of gaseous and solidcarbon dioxide, to a concrete mix in a ready-mix truck at a distance of5-100 cm from the surface, on average, such as 5-60 cm, for example 5-40cm, or 10-100 cm from the surface, on average, such as 10-60 cm, forexample 10-40 cm, from the surface of the mixing concrete. The dose ofcarbon dioxide delivered to the concrete may be any suitable dose, asdescribed herein, The carbon dioxide may be delivered for any suitablelength of time to reach the desired dose, for example, for 10-360seconds, or 20-360 seconds, or 30-360 seconds, or 45-360 seconds, or60-360 seconds, or 10-300 seconds, or 20-300 seconds, or 30-300 seconds,or 45-300 seconds, or 60-300 seconds, or 10-240 seconds, or 20-240seconds, or 30-240 seconds, or 45-240 seconds, or 60-240 seconds.

In any of these systems, e.g., a delivery system that includes a rigidor semi-rigid wand that is inserted into a fixed holder attached on ornear the drum of the ready-mix truck, flow of carbon dioxide may bemeasured and controlled as described herein; thus, the systems mayinclude a flow sensing apparatus that determines the appropriatetemperatures and pressures, and a controller that determines flow rateand time and determines total amount of carbon dioxide delivered to thedrum of the truck, where the controller automatically stops the flow orsignals to an operator who manually stops flow at the appropriate time,e.g., when a dose of carbon dioxide as described herein has been reachedfor the load of concrete in the truck.

Additional or alternative control systems and methods, such as thosedescribed in U.S. Patent Publication No. 20140373755, or PCT PublicationNo. WO2014205577, may be used. In certain embodiments, a control systemor method includes feedback mechanisms where one or more characteristicsof the concrete mix, and/or mixing apparatus and/or its environment ismonitored by one or more sensors, which transmit the information to acontroller which determines whether one or more parameters of the mixoperation requires modulation and, if so, sends the appropriate outputto one or more actuators to carry out the required modulation. Thecontroller may learn from the conditions of one batch to adjustprogramming for subsequent batches of similar or the same mixcharacteristics to optimize efficiency and desired characteristics ofthe mix. Sensors may include one or more temperature sensors, carbondioxide sensors, rheology sensors, weight sensors (e.g., for monitoringthe exact weight of cement used in a particular batch), moisturesensors, other gas sensors such as oxygen sensors, pH sensors, and othersensors for monitoring one or more characteristics of a gas mixture incontact with the concrete mix, a component of the concrete mixingapparatus, a component exposed to the concrete mix, or some other aspectof the mix operation. Sensors also include sensors that monitor acomponent of the concrete mix apparatus, such as sensors that detectwhen mixing has begun, when components of a concrete mix have been addedto a mixer, mass flow sensors, flow rate or pressure meter in theconduit, or other suitable sensors. Sensors, controllers, and actuatorsfor control systems and methods are described in greater detail in U.S.Patent Publication No. 20140373755, or PCT Publication No. WO2014205577,and any such system and/or method may be used in embodiments of thepresent invention. See, e.g., paragraphs 106-156 and FIGS. 1-3 of U.S.Patent Publication No. 20140373755.

Certain embodiments of the invention provide one or more of an orificeas described, a conduit operably connected to the orifice to direct thecarbon dioxide exiting the orifice, and, in some embodiments, a systemfor positioning the conduit so as to direct the carbon dioxide to aparticular location, for example, a particular location in a drum of aready-mix truck; the conduit apparatus may be affixed to the drum in apermanent or, preferably, temporary configuration. Certain embodimentsof the invention provide for the positioning system itself, alone oraffixed to a mixer, e.g., a ready-mix truck, or a plurality ofpositioning systems, each affixed to a separate mixer, e.g., to separateready-mix trucks. Thus, for example, in a ready-mix operation, eachtruck that is designated as a potential receiver of carbon dioxide mayhave its own positioning system, e.g., a holster, affixed thereto insuch a location as to position the conduit to deliver carbon dioxide toa desired location inside the drum of the truck while concrete is mixingin the drum, so that the conduit may be temporarily attached todifferent ready-mix trucks as desired to deliver carbon dioxide to thedifferent trucks. Hence, in certain embodiments, the invention providessystems and methods for delivery of carbon dioxide to the drums of oneor more ready-mix trucks where each truck to which carbon dioxide is tobe delivered has affixed thereto a positioning system that travels withthe truck, and a carbon dioxide delivery systems, for example asdescribed herein, that includes a conduit for delivery of carbon dioxidefrom a source of carbon dioxide to the ready-mix truck, where eachpositioning system is affixed in a location and position such that theconduit may be temporarily attached to the truck and positioned in sucha way as to allow carbon dioxide to be delivered to a desired locationwithin the drum of the truck, for example, while concrete is mixing inthe drum of the truck. Locations and positioning may be as describedherein. The system may include at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,12, 15, 20, 25, 30, 40, or 50 separate ready-mix trucks, each with itsown positioning system attached, and 1 or, in some cases, more than 1,such as 2, 3, 4, 5, or more than 5 carbon dioxide delivery systems thatinclude a conduit that may be temporarily attached to the trucks fordelivery of carbon dioxide from a source of carbon dioxide to the drumof the truck. The carbon dioxide delivery system may be positioned, whenin use, at a location where the truck or trucks normally halt for aperiod sufficient to deliver a desired dose of carbon dioxide to theconcrete in the truck, for example, at a location where the trucksnormally halt for at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes. Forexample, the delivery system may be positioned at a wash rack in abatching facility. In this way, carbon dioxide can be delivered to thetrucks without significantly altering the time the trucks remain in thebatching facility, as it is delivered during an operation that wouldnormally take place, e.g., washing the trucks, and the only potentialadditional time would be in the attachment and detachment of theconduit, and in some cases the starting and stopping of delivery of thecarbon dioxide, if done by the truck driver. Thus, the system andmethods may allow delivery of a desired dose of carbon dioxide to theready-mix trucks, such as a dose of 0.05-2% bwc, or any other dose asdescribed herein, without prolonging the average time that a truckremains in the batching facility by more than 1, 2, 3, 4, 5, 6, 7, 8, 9,or 10 minutes, for example, by no more than 2 minutes, or no more than 4minutes, or no more than 6 minutes, on average. The carbon dioxidedelivery system may be a liquid delivery system and further include anorifice that allows liquid carbon dioxide, or a mixture of liquid andgaseous carbon dioxide, under pressure, to be converted to solid andgaseous carbon dioxide as it passes through the orifice to an area oflower pressure, for example, to an area of atmospheric pressure, asdescribed herein. Systems and methods for monitoring the flow of carbondioxide, such as those described herein, may be included in the systemsand methods of delivering carbon dioxide to the drums of ready-mixtrucks. Systems and methods for controlling the flow of carbon dioxide,such as those described herein, such as starting, stopping, and/orotherwise modulating the flow, may be included in the systems andmethods of delivering carbon dioxide to the drums of ready-mix trucks.

In an alternative embodiment, each truck has an attached conduit, e.g.,a hose or pipe onboard for carbon dioxide delivery to its drum. This canbe, e.g., a line that mirrors the water input line on the truck fromjust above the water tank into the back of the truck. A flexible hose isconnected to this line when carbonated concrete is required, forexample, as indicated by a light that illuminates next to the hose inthe batch house; the orifice and other parts of the apparatus are, e.g.,proximal to the flexible hose. Once it is connected, a signal, such asfrom a sensor or a button press by the operator, indicates to the firstcontroller that the hose is connected and the system can deliver carbondioxide into the truck during the batching process. Once the delivery iscomplete, the line is disconnected and the operator can drive away.There can also be a safety to ensure the operator doesn't drive awaywith the line attached.

The systems and methods lend themselves to retrofitting of existingoperations, for example, retrofitting an existing ready-mix operation soas to allow delivery of solid and gaseous carbon dioxide to a desiredlocation in separate ready-mix trucks.

EXAMPLES Example 1

In this Example, the accuracy of the methods of flow determination wasverified by comparing total amount of carbon dioxide delivered asmeasured by change of weight to total amount of carbon dioxide deliveredas determined using the methods of the invention.

A system to deliver carbon dioxide to an orifice using carbon dioxidegas and carbon dioxide liquid was constructed, and carbon dioxide exitedthe orifice as a mixture of solid and gaseous carbon dioxide, asdescribed herein. Upstream temperature and pressure were measured, anddownstream temperature, and flow rates and total amount of carbondioxide delivered through the orifice were calculated as describedherein. The carbon dioxide was supplied from pressurized portable liquidcarbon dioxide tank (such as a Dewar), and the weight of the pressurizedportable liquid carbon dioxide tank (such as a Dewar) supplying liquidcarbon dioxide was measured before and after dosing (because liquidcarbon dioxide contributes far more than gaseous carbon dioxide to thetotal carbon dioxide delivered, the change in weight of the gaseoussource was not measured), so that total amount of carbon dioxidedelivered could be determined from total overall weight change. Thecalculated and measured total delivered amounts of carbon dioxide werecompared and the calculated values were found to vary no more than 10%from the measured values.

This Example demonstrates that the apparatus and methods of theinvention provide an accurate assessment of carbon dioxide flow anddelivery.

Example 2

An example of ready-mix injection system and wand is as follows:

System calculates CO₂ flow using the equations described herein.

Input comes from the customer in the form of a continuous signal(similar to that used in “admixture combined system”). System assumes amaximum flow rate and sends back signals for every X kg and system alsocounts these pulses so that it knows what the dose is for a particulartruck. This dose would be stored until the start button is pressed orthe system is otherwise activated, at which carbon dioxide deliverystarts. The system can delete the dose if the start button isn't pressedwithin the system timeout. 3-4 doses, or more, can be able to be storedand they would be injected in sequential order (ie. if there are 3doses, dose 1 would start upon the first press of the start button, thenwait for it to be pressed again for dose 2, which would be another truckand so forth). After the dose is received and the dose is known, thedose (in kg or lb) and the time batching started can be displayed in alist on an operations screen. The top entry can be the next to getinjected at the rack and any others would fall below it, in order. Therecan be an erase button that erases the selected dose from the list aswell as a swap button (or something similar) so that if a truck gets outof order, a batcher could “swap” the doses so that each truck gets theintended dose.

A human machine interface (HMI) can contain one recipe that can have amax flow rate setting, pause duration, max time for pause injection,system ID number, max CO₂ dose possible (kg or lbs, depending onlocation), system timeout, gas purge time (sec), pulse duration (ms), Xkg/pulse (kg), and Ghost flow rate (slpm) and initiation time (sec).

-   -   Max flow rate (slpm)—max flow of system, if it is reached,        system opens and closes valves to maintain that rate    -   Pause duration (sec)—duration of injection pause while system is        injecting. If this is “0”, then system injects at max flow until        the desired quantity is achieved. If a value is here, the system        calculates the injection as follows. It determines the time the        quantity would take at max flow, find the difference that time        and “max time for pause injection”, then divide that time by the        pause duration to determine the number of pauses and equally        distribute them during the injection. (ie. the system would        inject at full flow for a time, then pause, then inject, then        pause etc. until the injection is complete)    -   Max time for pause duration (sec)—maximum injection time while        the pause injection method is being used    -   System ID number—An ID number to identify the system when        looking at data    -   Max CO2 dose possible—Largest dose possible, if a higher dose is        received, the system will inject the max    -   System timeout (sec)—Time before system removes the truck from        the injection list if it hasn't been dosed    -   Gas purge time (sec)—Time for gas to purge output line/wand        after the desired quantity has been reached    -   Pulse duration (ms)—Length that 24 VDC pulse is output    -   X kg/pulse (kg)—Send pulse after each X kg of CO₂ is injected    -   Ghost flow rate (slpm)—Flow rate the system uses to send feed        back (system will assume this flow immediately upon receiving        signal 120 VAC from customer (can use a relay to get 24 VDC for        PLC)    -   Initiation time (sec)—Length of time systems waits from when        truck is batched until it actually starts injecting even if        start button is pressed before that time, however, the light        showing injection will illuminate once the button is pressed and        continue until injection is complete

System starts injecting when both the sensor is tripped in the lockingmechanism and the start button is pressed. When system is locked, orangelight illuminates, when system is injecting green light illuminates, andgoes off once complete. When complete, a blue light illuminates and if acritical alarm occurs, a red light comes on. Other colors may be used asdesired and appropriate. A buzzer shortly sounds when the wand is firstlocked in place.

System also records data via HMI. The system records the CO₂ doserequired, CO₂ dose received, plant number and time of day (both batchedand injected) for “Customer Data” for each injection. All other data,such as flow rates, sensor data, etc. can be recorded for engineeringpurposes. This data can be transferred to a central Main computer via acellular or hardwired router. This would also allow system access tochange software in PLC and HMI.

System Components:

PLC

HMI

Liquid valve

Gas valve

2 ball valves

2 PRV's

2 Pressure gauges

Orifice assembly

Temperature Probe

Pressure Sensor

Temperature Sensor for orifice

Vacuum jacketed hose from box to wand

Sensor for proper connection of wand

Red, Green, Blue and Orange lights

Buzzer

Start button

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. It should be understoodthat various alternatives to the embodiments of the invention describedherein may be employed in practicing the invention. It is intended thatthe following claims define the scope of the invention and that methodsand structures within the scope of these claims and their equivalents becovered thereby.

What is claimed is:
 1. An apparatus for delivering carbon dioxide to aconcrete mixer at a concrete facility comprising: (i) a source of liquidcarbon dioxide; (ii) a delivery line comprising a proximal end and adistal end, operably connected at the proximal end to the source ofliquid carbon dioxide, through which flows liquid carbon dioxide; (iii)an orifice operably connected to the distal end of the delivery line,through which the liquid carbon dioxide exits from the delivery line,wherein the diameter of the delivery line as it joins the orifice isD_(p) and the diameter of the orifice is D_(o), and wherein D_(o) isless than D_(p) and wherein the orifice is configured to convert theliquid carbon dioxide to a mixture of solid and gaseous carbon dioxide;(iv) a conduit, all of which comprises flexible material, with a lengthof at least five feet, leading from the orifice to a wand having anopening which is positioned to apply the mixture of solid and gaseouscarbon dioxide to concrete mixing in the mixer; and (v) a controller,wherein the controller determines a flow rate and amount of carbondioxide delivered to the mixer and outputs a signal to stop carbondioxide delivery when a predetermined dose of carbon dioxide has beendelivered.
 2. The apparatus of claim 1 wherein the opening of the wandis at least 5 cm, on average, from the concrete mixing in the mixer. 3.The apparatus of claim 1 further comprising a system to synchronizecarbon dioxide delivery to the mixer using signals from a programmablelogic computer (PLC) at the concrete facility.
 4. The apparatus of claim1 wherein the delivery line comprises a valve to adjust flow rate of thecarbon dioxide in the delivery line.
 5. The apparatus of claim 4wherein, for an incremental amount of carbon dioxide delivered to ahatching system at the concrete facility, the batching system processesa signal and sends a signal to close the valve in the delivery line whena. predetermined number of signals has been reached, wherein thepredetermined number of signals corresponds to a predetermined amount ofcarbon dioxide to be delivered to the mixer.
 6. The apparatus of claim 1wherein the concrete mixer is a transportable mixer.
 7. The apparatus ofclaim 6 wherein the concrete mixer is a drum of a ready-mix truck.